Abstract: A retainer for retaining a pair of bearing cups on an opposed pair of trunnions of a universal joint cross includes a strap having first and second end portions and an intermediate portion extending between the first and second end portions. The first and second end portions are adapted to be adhered to the pair of bearing cups on the pair of trunnions of the cross. The first and second end portions are adapted to be adhered to the pair of bearing cups by first and second adhesive elements. The retainer prevents the bearing cups from becoming lost during shipment. When the cross is received at a second manufacturing location, the retainer can be quickly and easily removed, without the use of any tools.

Abstract: A pressure control valve assembly is disposed in the hydraulic flow path of a differential assembly and is connected to a passageway leading to a limited slip device within the differential case to establish fluid communication there between. The invention includes a machined or formed blind hole, a groove which partially intersects the blind hole, a ball member seated in the blind hole, and a spring resiliently acting on the ball to apply a force biasing the ball into the blind hole. At the intersection of the blind hole and groove, an area, which is not sealed by the ball, is formed that provides a controlled leakage path for the hydraulic fluid. As the hydraulic fluid flow increases, the hydraulic pressure of the fluid on the pressure side increases which increases the force on the ball acting against the spring. As the pressure increases further, the resultant forces on the ball deflect the spring to increase the bleed area and increase the fluid bled proportionally to the fluid pressure.

Abstract: A low spring rate multi-convoluted collapsible spacer adapted for use as a bearing preloading element. The collapsible spacer comprises a substantially tubular body compressible in an axial direction thereof from a predetermined free length to a substantially shorter length. The tubular body includes a yielding zone and an elastic zone adjacent to said yielding zone. Each of the yielding and elastic zones has at least one convolution curved in the same radial direction. An average thickness of the body of the spacer in the elastic zone is substantially greater than an average thickness of the body in the yielding zone that provides the collapsible spacer a substantially higher resiliency in the axial direction in the elastic zone than in the yielding zone. As a whole, the collapsible spacer has a relatively low spring rate, thus larger amount of “spring back”, hence less sensitivity to wear and maladjustment.

Abstract: A method for manufacturing a driveshaft assembly takes advantage of the asymmetrical nature of the driveshaft tube and end fittings to reduce the initial imbalance of the driveshaft assembly. The method includes the initial steps of providing a driveshaft tube having a heavy side and providing an end fitting having a heavy side. The heavy side of the end fitting is aligned so as to be opposite the heavy side of the driveshaft tube. Finally, the driveshaft tube and the end fitting are secured together. The dimensional characteristics of the driveshaft tube and end fitting improve the balancing capability of the driveshaft assembly by permitting levels of imbalance of the driveshaft assembly to be lowered and better-managed.

Abstract: A driveshaft assembly is balanced for rotation during use by initially disposing an annular band about a portion thereof. The band is then secured to the driveshaft assembly, such as by welding, adhesives, frictional engagement, and the like. After the band is secured to the driveshaft assembly, one or more balance weights can be secured to the band, such as by welding, adhesives, and the like, at desired locations to balance the driveshaft assembly for rotation. The band functions as a mounting surface upon which the balance weights can be secured to balance the driveshaft assembly for rotation. Because the balance weights are secured not directly to the driveshaft assembly, but rather are mounted indirectly thereon by the band, the driveshaft assembly is protected from damage that might otherwise result from welding the balance weights directly thereto.

Abstract: A method for re-shaping portions of a coating applied to the surface of a component using a tool including a collet having a plurality of flexible arms with a wheel rotatably supported on each of the flexable arms, a nut and a sleeve. The tool is initially installed by disposing the collet caxially about the component. Then, the sleeve is disposed co-axially about the collet. Next, the nut is threaded onto a threaded first end of the collet. As the nut is threaded onto the collet, it engages and moves the sleeve axially toward the arms of the collet thereby causing the arms to be compressed radially inwardly such that outer circumferential surfaces of the wheels engage and re-shape the coating on the outer surface of the component. The tool, as a whole, can then be moved axially back and forth along the surface of the component to re-shape the entire length of the coating thereon.

Abstract: A retainer for retaining a pair of bearing cups on an opposed pair of trunnions of a universal joint cross includes a pair of cup-shaped end portions that are connected together by an intermediate strap portion. The retainer is expandable from a contracted size, wherein the cup-shaped end portions are spaced apart from one another by a first distance, to an expanded size, wherein the cup-shaped end portions are spaced apart from one another by a second distance that is greater than the first distance. The retainer, or at least a portion thereof, is preferably formed from a single material that is relatively flexible, stretchable, or otherwise expandable to permit the retainer to be selectively expanded from the contracted size to the expanded size. During installation, the retainer is initially expanded to the expanded size to allow the end portions to be disposed about the bearing cups supported on the trunnions of the universal joint cross.

Abstract: An improved female splined member includes a female tubular member having an inner surface provided with a plurality of longitudinally extending grooves that are sized and spaced in accordance with a desired number and position of splines to be formed. A plurality of elongate rods is disposed in respective longitudinally extending grooves formed in the inner surface of the female tubular member. A quantity of positioning material is provided within spaces provided between the elongate rods and the longitudinally extending grooves. The positioning material is hardened to support the elongate rods in the longitudinally extending grooves to define a plurality of inwardly extending splines in the female splined member. An improved method for manufacturing a female splined member includes the initial step of providing a female tubular member having an inner surface provided with a plurality of circumferentially spaced, longitudinally extending grooves.

Abstract: A method of manufacturing a driveshaft for use in a vehicular drive train system includes the initial step of providing an inner tube including a portion having a plurality of splines formed therein. A portion of an outer tube is then disposed about the portion of the inner tube in an overlapping or telescoping manner, preferably in a press fit relationship. Next, portions of the outer tube are deformed radially inwardly about the inner tube. The radially inwardly deformed portions of the outer tube that extend between the external splines of the inner tube define internal splines on the outer tube. The internal splines formed on the outer tube cooperate with the external splines formed on the inner tube to provide a rotational driving connection between the inner tube and the outer tube, while normally preventing relative axial movement therebetween.

Abstract: A wrap spring activated torque coupling is applied to a torque transmission coupling and/or a locking differential for a motor vehicle. The wrap-spring torque coupling allows for quick engagement and disengagement of an input member to an associated output member at large torsional capacities that exceed the limit of what is taught by prior art. The ability to quickly lock and unlock a vehicle differential under either a torsionally loaded or unloaded condition is realized by this application of the wrap spring activated torque coupling. Moreover, a two piece bi-directional wrap spring hub design is utilized that allows for simple turning and broaching operations for use in its manufacture, thereby eliminating a conventional deep annular counterbore that would require the use of much more expensive machining processes.

Abstract: A differential assembly for a motor vehicle comprises a differential case rotatably supported in an axle housing and forming an inner cavity housing a differential gear mechanism. The differential gear mechanism includes at least one pinion mate gear rotatably supported by a pinion shaft extending through radial bores in the differential case. The pinion mate gear has a back face adapted to cooperate with a complementary pinion seat surface through a thrust washer disposed therebetween. The differential case further includes at least one lubrication passage formed within the differential case adjacent to the radial bore receiving the pinion shaft. The lubrication passage provides fluid communication path for the lubricating oil from an oil reservoir in an axle housing to a space between the pinion seat surface of the differential case and the thrust washer of the pinion mate gear.

Abstract: A radial, bi-directional overrunning clutch is provided that supplies on-demand power to, for example, the front wheels of a vehicle, while allowing the front wheels to overspeed the rear wheels. The clutch comprises a driving member having a plurality of radially-outwardly-biased pawls, a reversing ring, a driven member having a plurality of notches, and a housing having a plurality of pawls. The pawls on the driving member engage outwardly concentric notches on the driven member, and are activated and deactivated by inner reversing cams of the reversing ring. The pawls in the housing engage notches in the outer surface of the reversing ring, which causes the reversing ring to move between a first position and second position relative to the driving member. The engagement of the housing pawls with the reversing ring notches is regulated by the driving member.

Abstract: An apparatus designed to set up gear testers and lappers for both above and below center engaged hypoid gear sets. The set-up gage includes a pinion stem and a gage body. The gage body has at least two sets of surfaces to properly position a simulated ring gear within the gear tester for each of the above and below center engaged hypoid gear set arrangements.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.

Abstract: A wheel end assembly in a steering beam axle for use in a motor vehicle. The wheel end assembly comprises a tube yoke attached to an axle tube defining an axle centerline, a steering knuckle defining a steering knuckle centerline, a driving axle shaft rotatably disposed in the axle tube, a live spindle rotatably supported by the steering knuckle, a stub shaft extending through the live spindle and rotatably coupled thereto, and a universal joint connecting the driving axle shaft and the stub shaft. The steering knuckle is pivotally coupled to the tube yoke through a pair of vertically spaced swivel joints defining a steering axis. The wheel end assembly further includes a knuckle centering adjuster for adjusting the knuckle centerline by selectively moving said steering knuckle relative to said tube yoke along said steering axis in order to align the knuckle centerline to the axle centerline.

Abstract: A hydraulically actuated torque-coupling device is provided for selectively actuating a secondary drive axle of an All-Wheel Drive motor vehicle when wheel slippage occurs with a primary axle. The torque-coupling device comprises a housing, an input shaft and an output shaft both rotatably supported within the housing, a selectively engageable friction clutch assembly for operatively coupling the input shaft to the output shaft, and hydraulic clutch actuator. The hydraulic actuator includes a hydraulic pump located within the housing and adapted to generate a hydraulic pressure to frictionally load the friction clutch assembly, and a variable pressure relief valve assembly fluidly communicating with the hydraulic pump to selectively control the hydraulic pressure generated by the pump. The variable pressure relief valve assembly includes an electro-magnetic actuator for selectively varying a release pressure of the pressure relief valve assembly based on a magnitude of an electric current applied thereto.

Abstract: A slip joint includes a structure that prevents a negative pressure situation from occurring within a sealed lubricant chamber during operation thereof. The slip joint includes a male splined member having a plurality of external splines formed thereon that cooperate with a plurality of internal splines formed on a female splined member. The cooperating splines are disposed within a lubricant chamber defined at one end by a seal assembly and at the other end by a pressure regulator assembly that maintains a positive pressure situation within the lubricant chamber during operation thereof (i.e., a situation where the fluid pressure within the lubricant chamber is greater than or equal to than the fluid pressure outside of the lubricant chamber). To accomplish this, the pressure regulator assembly includes a housing having an open end that faces toward the lubricant chamber. A spring urges the pressure compensator assembly toward the lubricant chamber.

Abstract: A divider for use in a stacking system for shipping of products in multiple layers in association with a pallet. The dividers are stackable and nestable with one another and with the pallet, and include a retaining wall to prevent movement of products off of an upper supporting surface thereof. The divider may be molded of a high-density, polymeric material to form a strong, rigid and durable divider which may be reused. As the dividers are nestable within one another and a pallet with which they are used, reshipping of multiple dividers for reuse is simplified.

Abstract: A full mold casting process in which a complete, positive model made of a thermally decomposable material is placed in a molding box and filled with sand; the sand is hardened by shaking. Casting metal is poured on the thermally decomposable model and the model is decomposed by the casting heat. In order to fill up the cavities of the model and mold moldings with crucial cavities, reliably with the molding sand, the model is provided with pass-through apertures. By introducing the flow-through holes into the casting model, preferably through the flange and button sides, all cavities of the casting model are completely filled with sand and the latter is compressed against the model. The rising of the sand in the model cavity is facilitated by the fact that the filling level of the molding sand is kept nearly constant near the model cavity to be filled until the cavity is completely filled.

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.