Abstract: A magnetic pulse welding operation is performed to secure first and second metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke. An inductor axially is positioned co-axially about the overlapping portions of the end of the driveshaft tube and the body portion of the yoke. The inductor is energized to perform a magnetic pulse welding operation to secure the end of the driveshaft tube to the body portion of the yoke without generating a significant flow of air toward the inductor.

Abstract: A method of assembling components of a universal joint, such as a cross and a yoke, positions and maintains the rotational center axes thereof in co-axial alignment during the assembly process. The universal joint includes a yoke including a body portion and first and second arms, wherein the first and second arms have respective openings formed therethrough. The universal joint also includes a cross including a body portion having a plurality of trunnions extending outwardly therefrom. Initially, an assembly tool having a recess formed therein is supported on the yoke such that the recess is precisely positioned relative to the rotational center axis of the yoke. Then, the cross is supported on the assembly tool such that one of the trunnions is received within and supported by the recess formed in the assembly tool. As a result, the rotational center axis of the cross is co-axially aligned with the rotational center axis of the yoke.

Abstract: An apparatus for supporting a workpiece, such as a yoke having a body portion and a pair of opposed yoke arms, during a magnetic pulse welding operation includes a lower jaw, an upper jaw, and a support pin extending therebetween. During the magnetic pulse welding operation, the lower and upper jaws of the support apparatus engage the opposed yoke arms, and the support pin extends through respective openings formed through the opposed yoke arms. The support apparatus can also include a counter die that is disposed between the lower jaw and the upper jaw and has an arcuate recess formed therein that receives the outer portions of the opposed yoke arms therein. Lastly, the support apparatus can further include a pair of positioning rails that engage the body portion of the yoke. As a result, the support apparatus prevents deformation of the opposed yoke arms and absorbs shock waves that can be propagated through the yoke during the magnetic pulse welding operation.

Abstract: A rolling ball spline type of slip joint includes a first tubular member having a plurality of inwardly extending regions formed therein. The first tubular member has a wall thickness that is essentially uniform throughout the circumference thereof. The slip joint also includes a second tubular member having a plurality of outwardly extending regions formed therein. The inwardly extending regions of the first tubular member are radially aligned with the outwardly extending region of the second tubular member to define a plurality of longitudinally extending raceways. The second tubular member has a wall thickness that is essentially uniform throughout the circumference thereof. A plurality of balls is disposed in each of the raceways for transmitting rotational force between the first and second tubular members, while accommodating a limited amount of relative axial movement therebetween.

Abstract: A magnetic pulse welding operation is performed to secure first and second metallic components together, such as a yoke and a driveshaft tube in a vehicular driveshaft assembly. The yoke includes a first portion, such as a body portion, and a second portion, such as a pair of opposed yoke arms, that are separated by a bridge portion. The end of the driveshaft tube is disposed co-axially about the body portion of the yoke, and a magnetic pulse welding operation is performed to secure the end of the driveshaft tube to the body portion of the yoke. The bridge portion can be defined by a groove formed in either the outer surface or the inner surface of the yoke. The groove may have side portions that extend either generally perpendicular or are angled or tapered relative to an axis of rotation of the yoke. If desired, a pair of opposed, semi-circular grooves may be formed in the yoke to define the bridge portion.

Abstract: A peripheral flange formed on a differential case for mounting a ring gear and the peripheral flange is provided with a plurality of cast-in bolt holes for bolting up the ring gear to the differential case using the lost foam casting process for making the differential case. A method of making a gear case eliminates the process of machining of the bolt holes in the differential case casting, thus reducing cost of manufacturing the differential case.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: A center bearing assembly rotatably supports an intermediate portion of a vehicle driveshaft assembly during use. The center bearing assembly includes a rigid bracket that is secured to a support surface of the vehicle, a support member that is supported within the rigid bracket, and an annular bearing that is supported within the support member for rotatably supporting the intermediate portion of the vehicle driveshaft assembly. The support member is formed from a resilient material and has a cavity formed therein. A plurality of bladders is disposed within the cavity formed in the support member. Each of the bladders is filled with a quantity of a rheological fluid. Fluid communication between adjacent pairs of the bladders is provided by respective control valves. A control circuit is provided for selectively generating and applying an energy field to each of the control valves so as to vary the ability of the rheological fluid to flow therethrough between the associated pair of bladders.

Abstract: A mounting system for coupling attaching mounting a steering gear housing member to a vehicle frame, comprises at least one single-piece steering gear bracket secured to a cross member of the vehicle frame, and at least one corresponding single-piece steering gear joint member integral with the steering gear housing member and secured to the steering gear bracket.

Abstract: A vehicle drive train assembly includes a source of rotational power and at least one rotatably driven vehicle wheel. A male splined member and a female splined member are connected between the source of rotational power and the vehicle wheel to transmit rotational power therebetween. At least one of the splined members is a driveshaft. The splines of the male splined member have side surfaces and outer surfaces which are convex in shape. The convex splines of the male splined member cooperate with the splines of the female splined member to connect the splined members together in a manner that allows for limited angular and axial movement therebetween.

Abstract: A method for determining a thickness of a shim for setting up a predetermined preload of a bearing assembly that rotatably supports a shaft within a housing. The bearing assembly includes front and rear tapered roller bearings. The shim is disposed between a bearing supporting shoulder of the shaft and an inner cone of the rear bearing. The method comprises the steps of: measuring a distance X from an end face of the shaft to the bearing supporting shoulder thereof; measuring a height B of the inner cone; mounting the shaft within the housing; applying a load to the inner cone of the rear bearing corresponding to a predetermined preload; measuring a distance XL from the end face of the shaft to the inner cone of the rear bearing; and determining the thickness W of the shim in accordance with the following equation: W=X?XL?B.

Abstract: An improved engine oil pan and transfer case assembly is provided wherein an oil reservoir and a first transfer case housing portion are unitarily combined. The first transfer case housing portion is adapted to combine together with a second transfer case housing portion to form a complete transfer case housing.

Abstract: A slip joint includes first and second shafts that are connected for concurrent rotational movement and for relative axial movement, such as by respective pluralities of axially extending spline. A seal can is secured to the first shaft and extends about a portion of the second shaft. A seal assembly is secured to the second shaft and engages a portion of the seal can. The seal assembly includes first and second seals that are each generally concave in shape. Each of the first and second seals is generally V-shaped in cross section, having a radially innermost end, an intermediate portion, and a radially outermost end, wherein the radially innermost and outermost ends are located closer to one another than the radially intermediate portions. the first and second seals are axially spaced apart from one another so as to define an annular space therebetween that can be filled with a sealing material, such as a waterproof grease.

Abstract: A universal joint assembly includes a cross and an end fitting having respective rotational centers that are precisely co-axially aligned with one another to minimize rotational imbalance. The cross has a pair of outwardly extending trunnions, upon which respective bearing cups are rotatably supported. A span control sleeve is press fit about each of the bearing cups. Each of the span control sleeves includes an outwardly extending flange portion that is precisely located relative to the rotational center of the cross. The end fitting is formed having a pair of inwardly facing surfaces that are precisely located relative to the rotational center of the end fitting. When the cross is assembled with the end fitting, the outwardly extending flange portions of the span control sleeves abut the inwardly facing surfaces of the end fitting. As a result, the rotational center of the cross is precisely aligned with the rotational center of the end fitting.

Abstract: A differential drive gear assembly including a differential case driven by a transmission allowing differential rotation between a pair of output axle shafts and facilitating a driving connection to a power take-off unit. The differential case has gear teeth directly formed thereon along an outer peripheral surface. The differential case gear teeth engage a power take off gear to drive an auxiliary device. In the preferred embodiment, the power take of device is a second drive shaft for driving a second axle assembly. Such an arrangement facilitates a simple conversion from an existing two-wheel drive design to a four-wheel drive assembly.

Abstract: An apparatus to regulate and control the temperature of an axle assembly for a vehicle. A heat pipe is inserted though the axle housing cover, the heat pipe travels the length of the cover. Near the lower region of the carrier and beneath the lubricating fluid level, the heat pipe bends to continue in the horizontal direction. Disposed about the terminal end of the heat pipe below the lubricating fluid line are a series of cooling fins. Heat generated within the lubricating fluid that is heated during operation conduit is dissipated via the cooling fins.

Abstract: A method is provided for quickly and inexpensively balancing an article, such a driveshaft tube for use in a vehicular driveshaft assembly, for rotation about an axis. Initially, a balancing structure is provided that includes a chamber that contains a quantity of a first component of a balancing material. The balancing structure is secured to the article. Then, a quantity of a second component of the balancing material is disposed within the chamber so as to initiate solidification of the balancing material. Lastly, before the balancing material solidifies, the article and the balancing structure are rotated so as to cause the balancing material to move within the chamber to a position wherein the combined assembly of the article and the balancing structure are balanced for rotation. The balancing material solidifies in this position, thus permanently balancing the article for rotation.

Abstract: The vehicular axle assembly includes an input shaft, a drive gear assembly connecting the input shaft to a pair of output shafts, pair of opposite wheel ends mounted to the outboard ends of the output shafts, a pair of wheel end disconnect assembly disposed between and selectively connecting each of the pair of the output shafts to the corresponding one of the wheel ends, and a control system controlling the wheel end disconnect assemblies to selectively transfer torque from the input shaft to either the wheel ends. Each of the wheel end disconnect assemblies has a hydraulically actuated friction clutch assembly integrated with the corresponding wheel ends for facilitating both selective torque coupling and limited slip between the wheel ends and the corresponding output shafts. The friction clutch assemblies are actuated by a hydraulic actuator, also adapted to supply pressurized hydraulic fluid to a vehicle wheel brake system.

Abstract: A vehicular drive shaft assembly is balanced about an axis of rotation. The vehicular drive shaft assembly includes a drive shaft tube having a first end and a second end, with a first tube yoke including a first radially outer wall fixedly mounted to the first end of the drive shaft tube. A first balance pendulum is located radially inward of the first outer wall and rotationally fixable relative to the first tube yoke, and a second balance pendulum is located radially inward of the first outer wall and is also rotationally fixable relative to the first tube yoke. The balance pendulums can be rotated before being locked in place in order to account for imbalances in the drive shaft assembly. A second tube yoke fixedly mounted to the second end of the drive shaft tube may also include balance pendulums, similar to the first, in order to provide additional drive shaft assembly balancing capabilities.

Abstract: A method for rotatably balancing a driveshaft includes the initial step of using a conventional balancing apparatus is used to determined the size and location of the balance weights needed to properly balance the driveshaft. Next, an adhesive material is applied to either or both of the driveshaft and the balance weight. The balance weight is preferably formed having an inner surface that is curved to conform with the curvature of the outer surface of the driveshaft. The preferred balance weight is further formed having a relatively thin outer peripheral rim portion having a plurality of radially outwardly extending teeth formed thereon. The overall size of the balance weight may be varied to provide differing amounts of weight for facilitating the balancing process.