Abstract: A power takeoff unit for an automotive vehicle being a normally front-wheel drive vehicle that is convertible to all wheel drive. The takeoff unit includes an input shaft supported in a housing, the input shaft is torsionally connected with a transmission of said vehicle. An output shaft concentric with the input shaft is provided, the output shaft is torsionally connected with the rear wheels of the vehicle. A shift collar to selectively connect said input shaft with said output shaft is provided. A shift fork is provided to translate the shift collar, the shift fork having a main body with a bore. A cylinder is connected with the housing. A piston is slidably mounted within said cylinder. A headed fastener is provided with a shank extending through the shift fork main body bore. The fastener head engages the shift fork, the fastener's shank being threadably engaged with the piston to capture the shift fork with the piston.

Abstract: A driveline (12) of a motor vehicle having an internal combustion engine (10) for propelling the vehicle and method of assembly can include a self-contained drive axle assembly (35). The self-contained drive axle assembly (35) can include an electric motor (18) for propelling the motor vehicle mounted coaxial with and sheathing a first portion of the drive axle assembly (35) and a disconnect clutch (20) mounted coaxial with and sheathing a second portion of the drive axle assembly (35) for selectively connecting powered rotation between the electric motor (18) and a gear box (14). The drive axle assembly (35) can include the gear box (14) having at least one of a transmission (15) and a power take off unit (40) mounted coaxial with and sheathing a third portion of the drive axle assembly (35) for transferring powered rotation to a pair of wheels (16a, 16b) through the drive axle assembly (35).

Abstract: A number of variations may comprise a method comprising: a lubrication system for a transfer case comprising: actively managing an oil level in a plurality of sumps in a transfer case by rotating at least one rotating element in the transfer case to transfer oil through the transfer case to lubricate the transfer case.

Abstract: A power takeoff unit for an automotive vehicle being a normally front-wheel drive vehicle that is convertible to all wheel drive. The takeoff unit includes an input shaft supported in a housing, the input shaft is torsionally connected with a transmission of said vehicle. An output shaft concentric with the input shaft is provided, the output shaft is torsionally connected with the rear wheels of the vehicle. A shift collar to selectively connect said input shaft with said output shaft is provided. A shift fork is provided to translate the shift collar, the shift fork having a main body with a bore. A cylinder is connected with the housing. A piston is slidably mounted within said cylinder. A headed fastener is provided with a shank extending through the shift fork main body bore. The fastener head engages the shift fork, the fastener's shank being threadably engaged with the piston to capture the shift fork with the piston.

Abstract: A driveline (12) of a motor vehicle having an internal combustion engine (10) for propelling the vehicle and method of assembly can include a self-contained drive axle assembly (35). The self-contained drive axle assembly (35) can include an electric motor (18) for propelling the motor vehicle mounted coaxial with and sheathing a first portion of the drive axle assembly (35) and a disconnect clutch (20) mounted coaxial with and sheathing a second portion of the drive axle assembly (35) for selectively connecting powered rotation between the electric motor (18) and a gear box (14). The drive axle assembly (35) can include the gear box (14) having at least one of a transmission (15) and a power take off unit (40) mounted coaxial with and sheathing a third portion of the drive axle assembly (35) for transferring powered rotation to a pair of wheels (16a, 16b) through the drive axle assembly (35).

Abstract: A number of variations may comprise a method comprising: a lubrication system for a transfer case comprising: actively managing an oil level in a plurality of sumps in a transfer case by rotating at least one rotating element in the transfer case to transfer oil through the transfer case to lubricate the transfer case.

Abstract: A clutch assembly which incorporates brushless motor technology to engage a clutch pack to cause two shafts to rotate in unison. The clutch actuation assembly includes a clutch apply member, a base plate disposed about an axis, a cam plate disposed about the axis, and at least one cam, operably associated with the base plate and the cam plate. At least one load transferring member operably associated with the at least one cam, as well as an actuator for providing relative rotation between the cam plate and the base plate about the axis, causing the at least one load transferring member to move with respect to the at least one cam, and the cam plate to translate along the axis actuating said clutch apply member.

Abstract: The present invention is a transfer case incorporating the use of a single actuator having an input member selectively engagable to a primary output member, an actuator operatively associated with a clutch assembly and a range selector, a first one-way clutch operably associated with the actuator, and a second one-way clutch operably associated with the actuator. When the actuator is actuated in a first direction, the first one-way clutch will activate the range selector to couple the input member and the primary output member to have either of a direct drive ratio, or a reduced gear ratio. When the actuator is actuated in a second direction, the actuator will actuate the second one-way clutch to engage the clutch assembly, transferring rotational force from the primary output member to a secondary output member.

Abstract: The present invention is a clutch assembly which incorporates brushless motor technology to engage a clutch pack to cause two shafts to rotate in unison. The present invention is a clutch actuation assembly having a clutch apply member, a base plate disposed about an axis, a cam plate disposed about the axis, and at least one cam, operably associated with the base plate and the cam plate. The present invention also includes at least one load transferring member operably associated with the at least one cam, as well as an actuator for providing relative rotation between the cam plate and the base plate about the axis, causing the at least one load transferring member to move with respect to the at least one cam, and the cam plate to translate along the axis actuating said clutch apply member.

Abstract: An electromagnetic clutch assembly having a solenoid activated ball ramp operator provides reduced power consumption and improved control. The electromagnetic clutch assembly includes a primary or pilot friction clutch pack and a secondary or main friction clutch pack. An annular solenoid coil cooperates with an annular operator or plunger. When the coil is energized, the annular plunger translates and compresses the primary or pilot friction clutch pack. Activation of the pilot clutch pack retards motion of one of the members of the ball ramp operator which, in turn, compresses a secondary or main friction clutch pack disposed across the input and output members.

Abstract: This invention discloses a hinge for use in a door of a motorized vehicle. The hinge includes a first part rigidly connected to a frame of the vehicle and a second part rigidly connected to the door. The first and second parts of the hinge are both connected to a hinge pin which enables the second part to be rotatable relative to the first part upon opening and closing of the door. A compressible spring mechanism is rigidly connected to the first part and engagable against the second such that upon swinging of the door the spring is compressed. The second part includes two wheels such that the spring mechanism engages one of the wheels when the door is closed, it engages both of the wheels in a door position when the door is partially open, and engages the other detent wheel when the door is fully open.