Abstract: A novel arrangement of a limited slip differential assembly comprising a differential case housing a friction clutch assembly provided within a differential case for selectively restricting differential action and a hydraulic actuator assembly including a piston assembly and a bi-directional gerotor pump. The piston assembly includes a hydraulic piston disposed in a piston housing forming a pressure chamber. The piston housing is provided with a removable bleed plug defining a flow restricting bleed passage. The bleed plug is accessible from the outside of the differential assembly without disassembling thereof through an access hole in the differential case. By appropriately selecting a flow area of the bleed passage, the limited slip differential assembly may be tuned to define application rate of torque transfer of the friction clutch assembly.

Abstract: An inspection device for inspecting production of splined members wherein the splined members are inspected to ensure that when the splined member is matched with a corresponding splined hole in an automotive drive system, the splined 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 splined member. The combination gage includes a substantially cylindrical gage spacer, a splined ring gage, and a flush gage pin, which is associated with the splined ring gage, having a low end mark and a high end mark thereon. The markings indicate proper/improper axial length of the splined portion. The preferred embodiment is used to evaluate a drive pinion shaft of an automotive axle assembly.

Abstract: An adjustable mounting assembly for a steerable wheel assembly. A pin member is horizontally movably disposed within a slot formed in the lower arm of a yoke assembly. A ball joint forging is adjustably secured to the lower arm. The pin member extends between the lower arm and a ball joint forging to facilitate selective adjustment therebetween. A pair of set screws are secured to the lower arm to engage opposite sides of the pin member to selectively move the pin member within the slot. By simply rotating the set screws, the pin member is horizontally adjusted to selectively move the ball joint forging in a horizontal direction to adjust the caster of the wheel assembly. Horizontal slots are formed in the lower arm to align with boltholes formed in the ball joint forging to allow the forging to be bolted to the lower arm over a range of horizontal positions.

Abstract: A lubrication arrangement for an endless chain in a transfer case of four-wheel drive vehicles comprising a casing, an input shaft, a first output shaft drivingly connected thereto, a second output shaft spaced from the input shaft, and the endless chain selectively transmitting torque from the first output shaft to the second output shaft. The casing includes a lubricant reservoir and a torque transfer compartment housing the endless chain. The input shaft is rotatably mounted within the casing and extends into the lubricant reservoir. An oil pump is arranged within the lubricant reservoir for supplying the lubricant under pressure to the endless chain. The excess amount of the lubricant is returned back to the lubricant reservoir through a lubricant return port formed in the casing. The lubrication arrangement allows retaining only a minimum necessary amount of lubricant in the chain compartment, thus preventing the oil churning and aeration.

Abstract: A driveline system for a motor vehicle includes at least two propeller shafts and a driveline angle reducer disposed therebetween for drivingly interconnecting the propeller shafts at a fixed operating angle. The driveline angle reducer includes a housing rotatably supporting therewithin a fixed-angle constant-velocity joint. The housing of the driveline angle reducer is mounted to a vehicle body and contains a supply of a lubricant for lubrication of the constant-velocity joint. The driveline angle reducer allows propeller shaft operating angles to be in a range where conventional Cardan joints can be used in the driveline systems without causing excessive cyclic vibrations.

Abstract: A limited slip differential assembly comprises a friction clutch assembly and a clutch actuator assembly including an actuator motor, a clutch actuator, and a gear module for drivingly coupling the actuator motor to the clutch actuator. The gear module includes a casing having a first mounting flange for fixing the casing to a differential housing and a second mounting flange for fixing the casing to the actuator motor, two gear support arms outwardly extending from the first mounting flange into the differential housing through an opening therein, a gear shaft supported by the gear support arms, and a pair of coaxial reduction gear members drivingly coupled to the gear shaft. One of the reduction gear members is drivingly coupled to the actuator motor and the other of the reduction gear members is drivingly coupled with the clutch actuator.

Abstract: A method of controlling caster and/or camber angle by controlling the amount of heat input during the welding process associated with the axle tube brackets and other suspension components such as the lower control arm, spring seat, shock bracket and sway arm bracket. In other words, larger hot weld spots versus smaller cooler welds will distort the axle tube differently. If the design of a tube assembly has undesirable caster and/or camber angles due to distortions caused by the welding of suspension components, the weld can be tuned to distort the assembly to a desired caster and/or camber angle. For example, if the camber desired requires the axle tube to be deflected up, the travel speed of welds on the top side of the tube may be slowed thus increasing the heat input.

Abstract: A slip yoke assembly for a vehicle drive train assembly includes a yoke shaft having an externally splined shaft portion and a slip shaft having a hollow internally splined portion disposed co-axially about the shaft portion of the yoke shaft. The yoke shaft and the slip shaft are axially movable with respect to each other and are engaged with each other for transmitting torque from one to the other. A flexible boot is provided for protectively covering the connection between the two splined members. The boot has a first clamping end disposed about the yoke shaft and a second clamping end disposed about the slip shaft. The first clamping end has a plurality of loops spaced circumferentially about the first clamping end. The loops are shaped to receive a band clamp and to retain the band clamp in position with respect to the first clamping end. The second clamping end has a plurality of loops spaced circumferentially about the second clamping end.

Abstract: An three-quarter floating axle drive assembly comprising an axle housing having an elongated axle tube, a rotatable axle shaft extending through the axle tube, a hub member rotatably supported on the axle tube through an anti-friction bearing assembly and drivingly connected to an outboard end of the axle shaft, and an axle shaft retainer disposed at an inboard end of the axle shaft provided for preventing an outward axial displacement thereof.

Abstract: An apparatus and method to inductively heat beveled gear teeth. An inductor has an annular body with a plurality of projections for meshingly engaging beveled of the gear. An inductor coil or loop is associated with each of the projections and is at least partially disposed between successive gear teeth to induce a magnetic flux directly there through when engaging the beveled gear. By simply rotating the inductor relative to the beveled gear while simultaneously sending a current through the coil, successive gear teeth are treated. Preferably, the number of gear teeth differs from the number of projections, and the beveled gear is rotated sufficiently to ensure that each of the projections and associated coil engages each of the beveled gear teeth to facilitate a more uniform treatment.

Abstract: A cutter blade for use with a face hob type cutter for producing the teeth of spiral bevel and hypoid gear members by a continuous index, face hobbing process comprises a cutter blade shank having a cutting member provided at one end thereof. The cutting member includes a tooth side cutting edge having a given axial pressure angle, and a tooth topland cutting edge. The tooth topland cutting edge of the cutting member simultaneously forms a topland surface of the tooth of the gear member as the tooth is cut by the tooth side cutting edge of the cutting member.

Abstract: A bearing backlash adjuster for an axle assemby. A cylindrical body threadingly engages an inner surface of a housing wherein rotation of the cylindrical body causes longitudinal displacement relative to the housing. An opening is formed through the housing providing direct access to the cylindrical body. The cylindrical body has bevel gear teeth formed adjacent one end proximate the opening. A tool is inserted through the opening to directly engage the cylindrical body. By simply rotation the tool, the cylindrical body can be cooperatively rotation to cause the body to move to a desired position relative to the housing. The movement of the cylindrical body enables adjustment of backlash or preload to the differential bearings to which the cylindrical body engages. Once the backlash is properly positioned, a locking pin is inserted within the opening to engage the bevel gear teeth to lock the cylindrical body in place.

Abstract: A differential mechanism includes a clutch pack disposed outside said differential case and has a first set of clutch plates splined onto one of said axle shafts and a second set of clutch plates splined onto a housing sleeve, wherein the housing sleeve circumscribes said axle shaft. A control mechanism comprising an actuator actuates the clutch pack. The housing sleeve is splined to a trunnion portion of the differential case. This device simplifies and reduces the cost of the original assembly and/or the optional mounting of a controlling or limiting device associated with a differential mechanism whose output elements are connected to coaxial wheel shafts.

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: An apparatus for quickly and efficiently balancing an article includes a pair of supports that are adapted to engage and support the ends of the driveshaft tube and to effect selective rotational and axial movement thereof. A system is provided for generating a representation of the shape of the outer surface of the driveshaft tube, such as by using a laser stripe generator and a digital camera. The laser stripe generator projects a relatively thin line of visible light onto the outer surface of the driveshaft tube. The digital camera receives the relatively thin visible line of light as it is reflected from the outer surface of the driveshaft tube and digitizes the reflected image into electrical signals. The apparatus further includes a system for generating a representation of the wall thickness of the driveshaft tube, such as by using an ultrasonic transducer.