Abstract: A method for forming complex contoured torque converter components with slots. A two dimensional blank is developed that will allow for the piercing of slots into a torque converter component while the blank is still essentially planar, as it proceeds through a progressive die.

Abstract: A limited slip differential assembly 100. The differential assembly 100 includes first and second housing portions 104, 106 which are formed by use of a flow-forming or spin-forming process and which respectively include an integrally formed splined inner surface 154, 156. The integrally formed splined inner surfaces 154, 156 are used to mate with clutch plates 146 which cooperate with clutch plates 144 to form clutch packs 150, 152. The novel splined engagement of clutch plates 146 and surfaces 154 and 156 provide improved durability, stiffness and torque capacity relative to prior designs.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A housing for differential mechanism is formed in two pieces using a cold flow-forming process. Each of the housing portions is formed with an internal hemispherical surface, and semi-circular recesses, which when aligned form circular recesses within which a pinion shaft is seated. A subassembly that includes the pinion shaft, pinion gears, side bevel gears, and a thin plastic liner surrounding the subassembly is located within a lower housing portion so that the pinion shaft is seated in the recesses. The upper housing portion is inserted within the upper portion and welded. A ring gear is joined to a housing portion.

Abstract: A lockup clutch assembly and fabrication method for a hydrokinetic torque converter having a clutch assembly located within the cover of the torque converter. The clutch assembly comprises a first friction disc drivably connected to the torque input member of a multiple ratio geared transmission and a second friction disc connected to the torque converter cover. The driving connection between the clutch and the cover is achieved by interlocking spline teeth which permit torque transfer through the clutch assembly while accommodating relative axial displacement therebetween. The cover includes a radial wall and a cold formed peripheral portion extending generally axially from said radial wall. The peripheral portion of the cover as formed has a surface with a substantially smooth circumference at an end distal from said radial wall.