Abstract: An axle assembly that is configured with reduced weight and an internal configuration that is configured to reduce losses through, for example, higher efficiency gearing, low viscosity lubricant and reduced lubricant levels as compared with current production automotive axle assemblies that are configured with a similar overall gear ratio and capacity.

Abstract: An axle assembly that is configured with reduced weight and an internal configuration that is configured to reduce losses through, for example, higher efficiency gearing, low viscosity lubricant and reduced lubricant levels as compared with current production automotive axle assemblies that are configured with a similar overall gear ratio and capacity.

Abstract: An apparatus that includes a first member, an insert, and an object. The first member made of a first metal and has a first exterior surface and a first end. A pocket is formed in the exterior surface of the first end. The insert is made of a second, different metal. The insert is connected to the pocket and has a second exterior surface that is flush with the first exterior surface. The object is formed of the second metal and is resistance welded to the insert. The second metal is steel and the first metal is a metal that cannot be resistance welded directly to steel.

Abstract: An apparatus that includes a first member, an insert, and an object. The first member made of a first metal and has a first exterior surface and a first end. A pocket is formed in the exterior surface of the first end. The insert is made of a second, different metal. The insert is connected to the pocket and has a second exterior surface that is flush with the first exterior surface. The object is formed of the second metal and is resistance welded to the insert. The second metal is steel and the first metal is a metal that cannot be resistance welded directly to steel.

Abstract: A method of forming a joint includes providing a first member made of cast iron having an exterior surface and a first end. A pocket is formed in the exterior surface of the first end. An insert made of steel is connected to the pocket. A second member made of cast iron is provided with an aperture. The method includes positioning the first end of the first member within the aperture and positioning a plug made of steel in the second member proximate the aperture. The plug is fixedly connected to the insert.

Abstract: A method of forming a joint includes providing a first member made of cast iron having an exterior surface and a first end. A pocket is formed in the exterior surface of the first end. An insert made of steel is connected to the pocket. A second member made of cast iron is provided with an aperture. The method includes positioning the first end of the first member within the aperture and positioning a plug made of steel in the second member proximate the aperture. The plug is fixedly connected to the insert.

Abstract: An axle housing assembly includes a cast iron tube having a pocket that is formed proximate a first end of the cast iron tube. The pocket is disposed generally transverse to a longitudinal axis of the cast iron tube. The axle housing assembly also includes an insert made of steel connected to the pocket. The steel insert permits the cast iron tube to be coupled to a cast iron carrier housing by welding steel plugs positioned in the carrier housing to the steel inserts.

Abstract: A vehicle axle assembly having an axle housing, an axle shaft and a sensor. The axle housing has a tubular portion. A flat is formed on an annular wall of the tubular portion proximate a distal end of the tubular portion. A hole, which intersects the flat, is formed through the tubular portion. The axle shaft can have an integrally formed target portion that includes a plurality of teeth. The sensor is mounted in the hole and abuts the flat to space a tip of the sensor apart from the teeth of the target portion by a predetermined distance.