Abstract: A driveshaft assembly includes a yoke including a body portion, a pair of opposed yoke arms that extends generally in a first axial direction from the body portion, and a neck portion that extends generally in a second axial direction from the body portion. A driveshaft tube is secured to the neck portion of the yoke, such as by magnetic pulse welding. A ring is secured to the body portion of the yoke, such as by press fitting, and a balance weight is secured to the ring, such as by welding.

Abstract: A hydraulic fluid plenum plate assembly in a torque-coupling assembly, non-rotatably mounted to a rotatable coupling case thereof so as to form a plenum chamber between the plenum plate assembly and the coupling case. The coupling case has an inlet port fluidly connecting the plenum chamber with a hydraulic pump disposed within the coupling case. The plenum plate assembly comprises a pickup tube for supplying a hydraulic fluid from a fluid reservoir to the plenum chamber. The pickup tube has inlet and outlet ends. The inlet end has an inlet opening submerged in the hydraulic fluid in the fluid reservoir. The outlet end has an outlet opening fluidly connecting the pickup tube with the plenum chamber. The outlet opening is disposed above the inlet port in the coupling case at any angular position of the coupling case relative to the plenum plate assembly.

Abstract: A journal cross includes a trunnion having a lubricant passageways formed therethrough. A retainer is disposed in the lubricant passageway and includes a body portion and a lip portion. The body portion of the retainer is retained within the lubricant passageway in a press fit relationship, and the lip portion of the retainer extends inwardly into the lubricant passageway. The bearing cup includes a thrust washer that is retained therein by needle bearings and a seal assembly. The thrust washer includes a projection that extends radially inwardly within the lubricant passageway and has one or more fingers provided thereon. When the bearing cup is installed on the trunnion, the fingers of the thrust washer cooperate with the lip portion of the retainer to retain the bearing cup on the trunnion, such as during shipment from one manufacturing location to another.

Abstract: A seal assembly provides a seal between a housing member and a shaft member extending through a bore formed in the housing member. The seal assembly comprises a seal member mounted to the housing member within the bore and about the shaft member and extending radially inward therefrom, an axially extending seal sleeve member provided to fit over the shaft in a fluid-tight manner for cooperating with the seal sleeve member, and a guide member extending radially outward from the seal sleeve member. The guide member has geometry provided for centrally locating the shaft within the bore in the tubular housing. The guide member is provided to protect the sealing integrity of the seal member when the seal assembly and the shaft member are assembled to one another. A method for installing the seal assembly with the guide member is also provided.

Abstract: An apparatus and method for performing a hydroforming process cause either or both of the opposed end portions of the workpiece to be deformed to achieve desired shapes therein. Initially, a workpiece having a pair of end portions is disposed within a die cavity defined by first and second die sections have cooperating recesses. A pair of end feed assemblies engage the end portions of the workpiece and deform such end portions to a desired shape. Pressurized fluid is provided within the workpiece either before, during, or after the deformation of the end portions of the workpiece to deform the central portion thereof it into a desired shape as defined by the die cavity.

Abstract: A hydraulic torque-coupling assembly that includes a pressure relief valve with an annular solenoid actuator assembly that moves axially to engage an annular valve actuator ring to selectively close a pressure relief valve disposed on the outer face of a torque-coupling case. The annular solenoid assembly does not include a conventional armature so that the coil portion of the solenoid actuator assembly moves into and out of engagement with the annular valve actuator ring. The valve actuator ring rotates with the torque-coupling case, however, the solenoid assembly does not rotate. The valve actuator ring and solenoid assembly are mounted outside the differential case. A variable amount of electrical current is applied to the solenoid assembly so that the release pressure of the pressure relief valve assembly is selectively based on the magnitude of an electric current supplied to the solenoid assembly.

Abstract: A lubrication system of an axle assembly comprising a differential carrier rotatably supporting a differential case therewithin, an axle tube extending outwardly from the differential carrier, a bearing assembly for rotatably supporting the differential case within the differential carrier, and an annular drain-back baffle formed with a drain-back hole passing through the drain-back baffle and defining an oil delivery passage between the differential carrier and the axle tube. The drain-back baffle is selectively positioned within the axle assembly to provide changeable oil flow characteristics of the axle assembly. A method is provided for controlling flow of lubricant between a differential gear and an axle tube by selectively adjusting the position of the drain-back channel in order to provide the desired lubricant flow path.

Abstract: A method for statistically analyzing the operation of a machine for balancing articles for rotation so as to reduce measurement errors and thereby enhance productivity and quality including the steps of collecting raw data during production balancing of articles for rotation, and statistically analyzing the data to determine appropriate process control limits for prompting investigative or corrective action if a process control limit is exceeded.

Abstract: A threaded fastener has opposite hand threads provided thereon for securing two components together, such as a companion flange and a flange yoke assembly that is used in a vehicular drive train system. The companion flange includes a hollow cylindrical sleeve portion and a disc-shaped flange portion having an aperture formed therethrough. The flange yoke includes a disc-shaped flange portion and a yoke portion having an aperture formed therethrough. The flange yoke aperture is aligned with the companion flange aperture. A threaded fastener extends through the companion flange aperture and the flange yoke aperture. The threaded fastener includes a first threaded portion having a first hand that is disposed within the companion flange aperture. The threaded fastener further includes a second threaded portion having a second hand that is disposed within the flange yoke aperture.

Abstract: A damper insert for assembly in a tubular drive shaft of a motor vehicle includes a tubular sleeve, a helically wound, resiliently deformable wiper secured to the sleeve, and a corrugated winding secured to the sleeve. The wiper includes an arch that spans mutually spaced supports. The damper insert is sized to fit in the bore of the drive shaft such that the arch frictionally engages the surface of the bore and secures the insert in place within the shaft with a resilient press fit. The arch projects radially outward toward the bore beyond the radially outer surface of the winding.

Abstract: A friction coupling assembly for a gear drive unit. The friction clutch assembly comprises an input member and at least one output member, a friction clutch for selectively coupling the input member with the at least one output member and an actuator assembly for selectively engaging the friction clutch. The actuator assembly includes a fluid pump operatively connected to the input member or the at least one output member through an auxiliary clutch, a fluid pressure accumulator in fluid communication with the fluid pump for storing a pressurized fluid generated by the fluid pump, and a fluid clutch actuator in fluid communication with the pressure accumulator for loading the friction clutch.

Abstract: A pressure switch or valve for a hydraulic circuit that responds primarily to fluid flow as opposed to relying strictly on a pressure gradient across the valve. A T-shaped valve has a stem portion disposed within an opening in a reservoir or other fluid passage. The valve is spring biased in an open position. A valve head has an area significantly larger than an area of the opening. As fluid flows around the edge of the valve head, the fluid speed increases and induces a pressure gradient across the valve head to overcome the spring bias and close the valve. The valve may be employed in a wall surface of the reservoir or fluid passage having an area significantly larger than the valve head.

Abstract: A method for assembling a speed-sensing device for monitoring an angular velocity of a rotatable shaft, comprises the steps of: providing a hollow housing having a speed sensor hole, installing a stopper plug into the speed sensor hole so that a stein portion of the stopper plugs extends into the housing, inserting a tone wheel into the housing and inserting the shaft into the housing until the shaft positively engages the tone wheel. The speed-sensing device comprises the tone wheel non-rotatably mounted to the shaft. The shaft has a shaft groove formed on an outer peripheral surface thereof, while the tone wheel has a wheel groove formed on an inner peripheral surface thereof. The speed-sensing device further includes a snap ring retainer provided to engage the complementary shaft and wheel grooves in order to prevent movement of the tone wheel along the shaft.

Abstract: A torque vectoring gear drive apparatus for controlling drive torque distribution. The gear drive apparatus comprises an input shaft, first and second output shafts, a planetary interaxle differential unit for transmitting torque from the input shaft to the first and second output shafts, and a speed gear assembly provided for overriding said planetary interaxle differential unit. The planetary differential unit includes a planet carrier drivingly coupled to the input shaft and rotatably supporting at least one planet gear, a sun gear drivingly coupled to the at least one planet gear and a ring gear drivingly coupled the first output shaft, the sun gear drivingly coupled to the second output shaft. The speed gear assembly selectively couples the input shaft to the sun gear to define a first drive mode in which the sun gear is driven at a first speed.

Abstract: A noise and vibration damper for use with a rotatable structure, such as a driveshaft assembly for a vehicular drive train system, includes an inner member, an elastomeric member that extends about the inner member, and an outer member that extends about the elastomeric member. The inner member is formed from a sheet of material that has been deformed to a desired shape, while the outer member is formed from a tube of material having a length that is selected to provide the desired dampening frequency. The natural resonant frequency of the noise and vibration damper can be adjusted by varying either or both of the shape of the inner member or the axial length of the outer member of the noise and vibration damper. In both instances, the weight distribution of the components of the noise and vibration damper is altered.

Abstract: A rigid drive axle assembly includes a support beam member having a substantially flat central plate section, a differential assembly module secured to the central plate section through at least two threaded studs extending from the central plate section. The differential assembly module includes a differential carrier frame member having two bearing hubs receiving differential bearings. A method for verifying a predetermined bearing preload of the differential assembly module comprises the steps of preloading the differential bearings to the predetermined bearing preload, inserting mounting bores in the bearing hubs of the frame member onto the mounting studs, and determining that the differential bearings are properly preloaded if the mounting studs are received in the mounting bores in the differential carrier frame member without substantial resistance, or determining that the differential bearings are not properly preloaded if the mounting studs may not be received in the mounting bores easily.

Abstract: A cross for use in a universal joint includes a lubrication system for positively causing lubricant to flow into the region of the bearings contained within a bearing cup mounted on the trunnion. The lubrication system includes a pump that is disposed in the lubrication passageway formed in the trunnion of the cross. In a first embodiment, the pump is embodied as a reciprocating piston pump, including a hollow cylindrical housing having a piston slidably supported therein. When the cross is rotated during use, the piston is moved radially outwardly relative to the housing, thereby injecting a quantity of lubricant from the lubricant passageway into the region of the bearings. When the cross is ceased to be rotated, the piston is moved radially outwardly relative to the housing under the urging of a spring. In a second embodiment, the pump is embodied as a rotatable auger pump.

Abstract: An integrated control system for a motor vehicle including at least one drive axle having left and right axle shafts each provided with a wheel mounted thereon. The integrated control system comprises a vehicle torque control system, a vehicle body roll control system, and a common source of a fluid pressure provided to operate both the vehicle body roll control system and the vehicle torque control system. The vehicle torque control system includes at least one fluid actuated clutch provided to regulate a drive torque distribution between the wheels of the motor vehicle in order to improve traction of the motor vehicle on a drive surface. The vehicle body roll control system includes at least one force device provided to tilt a vehicle body relative to a vehicle chassis so as to counteract a rollover-inducing force.

Abstract: A centering device for a double Cardan universal joint is comprised of a disc-shaped body having a first and second annular face and an annular rim extending about a central axis. A first hollowed protrusion is centrally located on the first annular face, and a second hollowed protrusion is centrally located on the second annular face. A plurality of bearings are built into the disc-shaped body, extending circumferentially about the central axis. The bearings may be contained within two races, with one race located on each annular face, or the bearings may be contained within holes or slots built into the disc-shaped body.

Abstract: A vehicular axle assembly includes an electrical generator for generating electricity to supply power to one or more electrical components therein during operation. The axle assembly includes a hollow housing that rotatably supports a differential mechanism therein. An input shaft is rotatably supported in the axle housing and terminates in a pinion gear. The pinion gear meshes with the differential mechanism that, in turn, rotatably drives a pair of output shafts that extend to respective driven wheels of the vehicle. A stator is supported within the axle housing about the input shaft, while a rotor is supported on the input shaft. When the input shaft is rotated, the rotor generates electrical power that may be used to operate the electrical component, such as a piezo-based device supported on a driveshaft assembly connected to the input shaft.