Abstract: A hydraulic coupling assembly is provided for an auxiliary drive axle of an all wheel drive motor vehicle. The hydraulic coupling assembly comprises a rotatable casing, first and second output shafts axially outwardly extending from said casing, at least one hydraulically operated, selectively engageable friction clutch assembly for operatively coupling the casing to at least one of the output shafts, and at least one hydraulic clutch actuator. The hydraulic actuator includes a hydraulic pump located within the casing 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 selectively for varying a release pressure of the pressure relief valve assembly based on a magnitude of an electric current applied thereto.

Abstract: An ultra narrow adjustable differential assembly includes a ring gear rotatably supported within a differential housing about a central axis, a set of differential pinion mate gears rotatably mounted to the ring gear, a pair of opposite side gears drivingly engaging the differential pinion mate gears for establishing driving connection between the ring gear and the side gears and allowing differential rotation between the side gears, and an adjustment device for selectively adjusting position of the ring gear relative to the differential housing and proper bearing preload.

Abstract: A differential assembly for a motor vehicle comprises a differential case rotatably supported in an axle housing, opposite output shafts drivingly connected to the differential case, a friction clutch pack for controlling the differential action, and a hydraulic clutch actuator for selectively fictionally loading the clutch pack. The hydraulic clutch actuator includes a variable pressure relief valve assembly to selectively control the friction clutch pack. The variable pressure relief valve assembly includes a valve closure member, a valve seat complementary to the valve closure member, and an electro-magnetic actuator for engaging the valve closure member and urging thereof against the valve seat with an axial force determined by a magnitude of an electric current supplied to the electro-magnetic actuator so as to selectively vary a release pressure of the pressure relief valve assembly based on the magnitude of the electric current.

Abstract: A simplified differential assembly includes a single-piece open-ended hollow differential case and a free-floating differential gear mechanism mounted therewithin. The differential case is provided with a plurality of axial grooves formed on an inner peripheral surface of the differential case and extending between opposite open ends thereof. The differential gear mechanism includes a pinion shaft rotatably supporting a plurality of pinion gears in a free-floating manner, and adapted to drivingly engage the axial grooves of the differential case. The differential case is axially adjustably supported within an axle housing by means of two opposite mounting members. The mounting members are rotatably supporting the differential case at the opposite ends thereof through anti-friction roller bearings. The single-piece differential case may be used for differential assemblies in both open and limited slip configurations.

Abstract: A compact differential assembly includes a differential case defining a cavity, a set of pinion mate gears rotatably mounted within the cavity in a free-floating manner, and a pair of opposite side gears drivingly engaging the differential pinion mate gears for allowing differential rotation between the side gears. Each of the side gears is integrally formed at an inward end of a corresponding axle shaft within an outside diameter thereof as a unitary single-piece part.

Abstract: A central tire inflation system for live spindle wheel ends comprising a steering knuckle secured to a vehicle, and a spindle assembly rotatably mounted about the steering knuckle. A drive shaft is rotatably disposed through the steering knuckle and is in driving connection with the spindle assembly. A rubbing slip-ring seal is mounted into a flange of the steering knuckle and defines a seal chamber between the knuckle flange on one side and the drive shaft and the spindle assembly on the other side. An inlet passageway is formed directly through the steering knuckle in communication with the seal chamber. The inlet passageway transmits pressurized air from a pressurized air source directly to the seal chamber. An outlet passageway is formed directly through the spindle assembly and is also in direct communication with the seal chamber to establish communication between the seal chamber and a pneumatic tire.

Abstract: An axially collapsible driveshaft includes a first driveshaft tube section, a connecting member having a first end portion that is secured to the first driveshaft tube section, and a second driveshaft tube that is secured to a second end portion of the connecting member. During normal operation of the drive train assembly, torque is transmitted through the driveshaft by means of the securement between the first driveshaft tube section, the connecting member, and the second driveshaft tube section. However, if a relatively large axial force is applied to the end portions of the driveshaft, either or both of the end portions of the connecting member are designed to fracture, allowing relative axial movement to occur between the first driveshaft tube section and the second driveshaft tube section. An annular recess may be formed in the connecting member adjacent to either or both of the end portions that are secured to the driveshaft tube sections.

Abstract: A transfer case housing includes a single-piece casing forming an interior compartment provided with an access opening for assembling components of the transfer case, and a casing cover member for closing the access opening. The casing is manufactured as a single-piece casting wherein bearing bores could be machined into the unitary single-piece casing. The interior compartment is adapted to house an appropriate torque transfer mechanism, such as constant four-wheel-drive, or “on-demand” four-wheel-drive, providing rear or front wheel drive (two-wheel-drive mode), or four wheel drive (four-wheel-drive mode), controlled automatically or manually by a vehicle operator.

Abstract: A dual disconnect differential assembly for four-wheel drive (4WD) vehicle is disclosed. This disconnect differential assembly connects/disconnects both output shafts of a differential assembly simultaneously from the respective universal joints of the drive assembly. Both output shafts are interconnected to provide simultaneous sliding along an axial direction. A clutch mechanism associated with the inboard side of each universal joint (which may be a constant velocity joint) and with the output shafts is provided for simultaneous connection and simultaneous disconnection of the output shafts from the outboard side of the universal joint. The dual disconnect differential assembly herein is simple, compact, and reliable. It overcomes the disadvantages associated with single axle disconnect mechanisms presently in use. It also provides a simpler, more compact, and more reliable dual disconnect differential mechanism than any such mechanism presently known.

Abstract: A method and apparatus for quickly and efficiently balancing an article, such as a tube for use in a vehicular drive shaft assembly, for rotation about an axis is provided. Initially, a balance ring is press fit or otherwise mounted onto the article to be balanced. The balance ring includes a ring of a material that can be selectively removed to balance the article for rotation, such as powdered metal. The article is mounted on an apparatus for rotating the article at a predetermined speed and for sensing vibrations that are caused by imbalances in the structure of the article. An electronic controller is responsive to such sensed vibrations for determining the size and location of one or more balance weights that, if secured to the article, will minimize or eliminate these imbalances.

Abstract: A gerotor assembly includes a pressure chamber with an integral eccentric ring for a motor vehicle hydraulic differential for use in hydraulic limited slip differentials for axles, transfer case center differentials and similar devices. The gerotor pump assembly in accordance with the present invention includes a housing having an integral ring which provides a pressure chamber for a piston, an eccentrically positioned recess for a inner rotor and an outer rotor and a location for a pressure limiting system. The gerotor pump assembly is of a non-reversing gerotor pump configuration using known methods to produce a unidirectional fluid flow.

Abstract: An apparatus for measuring the movements of a component in a drive train assembly, such as an axle housing in a vehicular drive train assembly, includes a motion transfer member having a first end that is connected to the axle assembly for movement therewith. A second end of the motion transfer member extends from the axle assembly into engagement with a measuring device that is supported co-axially with or relative to the axle assembly. The measuring device is responsive to the movements of the axle assembly for generating a signal that is representative thereof. The electrical signals generated by the measuring device are fed to an electronic controller for storage and/or analysis.

Abstract: A fixture for supporting a sensing device on a variety of differently sized and shaped articles and for protectively enclosing such a sensing device when the article is moved during use includes a base including a pair of spaced apart feet that engage the outer surface of the article. The feet defined a recessed area in the bottom surface of the base that can receive portions of the article therein regardless of the radius of curvature or other shape thereof. An enclosure area is provided in the base that can receive a sensing device therein. A lid cooperates with the base to provide a protective enclosure for the enclosed area and the sensing device disposed therein. The lid can be retained on the base by any desired retaining structure. A seal can be provided between the lid and the base to prevent dirt, water, and other contaminants from entering into the enclosed area when the lid cooperates with the base.

Abstract: A method for manufacturing a splined member, such as a male or female splined shaft, having a low friction coating applied thereto includes the initial step of providing a length of cylindrical stock having a predetermined outer diameter. The end of the cylindrical stock is then machined by any conventional process to form a preform including an end portion and a neck portion. Next, the end portion of the preform is subjected to a cold working process by a conventional roll forming machine or similar tool to form a plurality of splines about the circumference thereof. The cold working process is effective to re-shape the end portion of the preform to form the splines without the removal of any material therefrom. As a result, each of the splines is formed having a generally involute cross sectional shape, wherein opposed sides of the splines are relatively gently curved between the inner roots and the outer ends thereof.

Abstract: A hob type cutter blade for use in a hobbing process. The cutter blade is formed with at least one cooling passage that permits the flow of coolant through the cutter blade to the contact surface reducing the heat generation as well as dissipating any heat already produced during the hobbing operation. During manufacturing, the cooling passage is sintered into the carbide cutter blade without the addition of separate operation.

Abstract: A method for controlling an axle shaft endplay in a vehicle is disclosed. The desired axle shaft endplay is determined by a manufacturer based on the specific operating conditions of a differential assembly. In accordance with the endplay controlling method of the present invention, first the differential is partially assembled by mounting side gears and a set of differential pinion mate gears in a differential case. Then, the manufacturer determines a thickness of a shim ring disposed between an axle shaft retainer ring and the differential side gear, which would provide the desired endplay. The appropriate shim ring is selected from an endplay controlling kit comprising a plurality of the shim rings of assorted thickness. Next, axle shafts are inserted into the differential case through the side gears, and the selected shim ring is mounted to the axle shaft. Finally, the retainer ring is secured to the axle shaft.

Abstract: A balance weight is secured to a driveshaft tube for rotatably balancing the driveshaft tube during use. The balance weight includes a first inner layer of material and a second outer layer of material that are secured together to form an integral unit. The first and second layers of material may be secured together in any desired manner, such as by adhesives, pressure bonding, tinning, and the like. The inner layer is preferably sufficiently flexible to bend with the driveshaft tube during use and is preferably formed from a material that does not react with either the material used to form the driveshaft tube, the material used to secure the inner layer to the driveshaft tube, or the environment in which the inner layer is used in such a manner as to reduce the ability of the balance weight to be retained on the driveshaft tube. The inner layer can be formed from a stainless steel alloy having a relatively small thickness that allows it to bend with the driveshaft tube during use.

Abstract: An inspection device for inspecting production of threaded members wherein the threaded members are inspected to ensure that when the threaded member is matched with a corresponding threaded hole in an automotive drive system, the threaded member will mate properly to serve its intended purpose. The apparatus of the invention is formed as a three-piece gage assembly that checks for lead errors and length errors set forth in the threaded member. The combination gage includes a substantially cylindrical gage spacer, a threaded ring gage, and a flush gage pin, which is associated with the threaded ring gage, having a low end mark and a high end mark thereon. The markings indicate proper/improper axial length of the threaded portion. The preferred embodiment is used to evaluate a drive pinion shaft of an automotive axle assembly.

Abstract: A method for manufacturing a banjo-type drive axle housing for a motor vehicle is disclosed. The first step is the operation of forming the substantially identical upper and lower half members having a U-shaped cross-section along entire length thereof with radially extending wall sections. Each of the members is metal formed, such as by stamping or forging, from a blank sheet of steel. Next step is to select a desired box-section of an axle beam portions, and a desired size of an opening in a central portion of the axle housing. Then, if necessary, the wall sections of the housing half members are trimmed so that when assembled said housing half members provide the desired box section and size of the opening in the central portion of the axle housing. Finally, the trimmed housing half members are welded to each other to produce the axle housing.

Abstract: A hydraulically actuated friction coupling comprises a hollow case, an output shaft drivingly connected to the case, a friction clutch pack for selectively engaging and disengaging the case and the output shaft, and a hydraulic clutch actuator. The hydraulic actuator includes a hydraulic pump for generating a hydraulic pressure to frictionally load the clutch pack, and a piston assembly disposed within the case between the pump and the clutch pack. The piston assembly includes an annular pressure plate adjacent to the pump, an annular thrust plate axially spaced from the pressure plate and adjacent to the clutch pack, and a pair of concentric radially spaced resilient annular seal members bonded to the pressure and thrust plates so as to define an annular cavity within the piston assembly. The annular cavity in the piston assembly is in fluid communication with an output port of the hydraulic pump.