Abstract: The present invention allows for the pack clearance of a clutch pack to be adjusted during the manufacturing process to the proper amount, even if there are variations in friction disc thickness and steel disc thickness. The present invention is an electromagnetic clutch having an adjustable pack clearance arrangement, comprising an output shaft, a pressure plate, and a clutch pack actuated by the pressure plate. The pressure plate and the clutch pack are splined to the output shaft. There is also a clutch housing splined to the clutch pack, which also receives force from the clutch pack when the pressure plate is applied. The pressure plate defines a pack clearance for the clutch pack, and the pack clearance is adjustable by a pack clearance adjusting arrangement.

Abstract: A transfer case for AWD/4WD vehicle that employs a bushing positioned within a transfer case housing. The bushing is formed to the housing when the housing is cast. The bushing includes one or more axial notches formed in an outer surface of the bushing that fill with the housing metal during the casting process that prevents the bushing from rotating in response to a load from a slip yoke. A helical groove is formed in the inner surface of the bushing and a slot is formed through a housing wall along the bushing that allows lubricant from within the housing to flow through the bushing.

Abstract: An electromagnetic clutch for motor vehicle drive line applications includes a friction clutch pack, a ball ramp actuator and an electromagnetic coil. The ball ramp actuator includes a pair of circular members having opposed pairs of arcuate recesses receiving load transferring members and a torsion spring which provides a restoring force to return the circular members to their center, disengaged positions. Improved clutch control, particularly during disengagment, is achieved by this ball ramp actuator configuration.

Abstract: An electromagnetic clutch for motor vehicle drive line applications includes a friction clutch pack, a ball ramp actuator and an electromagnetic coil. The ball ramp actuator includes a pair of circular members having opposed pairs of arcuate recesses receiving load transferring members and a torsion spring which provides a restoring force to return the circular members to their center, disengaged positions. Improved clutch control, particularly during disengagment, is achieved by this ball ramp actuator configuration.

Abstract: A motor vehicle transfer case includes an input shaft and an electromagnetic brake for retarding rotation of the input shaft. An electromagnetic coil is mounted to the front of the transfer case about the input shaft. An armature plate is secured to the input shaft adjacent the electromagnetic coil. Energization of the coil retards rotation of the input shaft and cancels neutral drag torque from the transmission thereby eliminating relative rotation between the shifting elements of the transfer case and providing smoother shifts.

Abstract: A transfer case for AWD/4WD vehicle that employs a bushing positioned within a transfer case housing. The bushing is formed to the housing when the housing is cast. The bushing includes one or more axial notches formed in an outer surface of the bushing that fill with the housing metal during the casting process that prevents the bushing from rotating in response to a load from a slip yoke. A helical groove is formed in the inner surface of the bushing and a slot is formed through a housing wall along the bushing that allows lubricant from within the housing to flow through the bushing.

Abstract: A shift synchronizer for a motor vehicle transfer case includes a pair of blocker rings disposed on opposite sides of a plurality of circumferentially arrayed struts. The blocker rings include respective symmetrically disposed cone clutch faces. The clutch faces abut complementarily configured surfaces on the input shaft and the planet carrier of a planetary gear speed reduction assembly. The struts are spring biased radially inwardly by circumferentially extending tension springs and are received upon and detentingly engage a shift sleeve. The shift sleeve is splined to the transfer case output shaft. As the shift sleeve is translated axially toward either the input shaft or the planet carrier, the cone clutch face of the respective blocker ring is urged into contact with its adjacent complementarily configured clutch surface thereby frictionally engaging the output shaft with the input shaft or the planet carrier thereby causing such components to achieve synchronism.

Abstract: A two speed transfer case assembly includes a planetary gear speed reduction assembly, a shift sleeve for selecting either reduced speed drive through the planetary gear assembly or direct drive from the transfer case input. The planet carrier of the speed reduction assembly includes a band brake disposed thereabout. A linear actuator selectively, adjustably tightens the band brake to control retardation of the planet carrier thereby controlling the speed of the carrier and thus the output of the planetary gear assembly. This configuration cancels the drag torque typically applied to the input of a transfer case from the associated automatic transmission and minimizes or eliminates the relative rotation between the shifting elements in the transfer case allowing smoother shifts. When fully engaged, the planetary carrier brake can also serve as a wet parking brake.

Abstract: An apparatus for controlling a transmission includes a shifting actuator with an plurality of electric motors for shifting gears of the transmission. A load on the synchronizer is measured when shifting the gears of the transmission. The load is measured by sensors on the load fork. Compensating springs can alternatively be included. The position of the fork relative to the synchronizer mechanism is determined by a position sensor in communication with the rod or in communication with the load fork itself.

Abstract: A transfer case includes a clutch assembly having a disc pack clutch, a cone clutch and a lockup hub or collar. All three clutch components are disposed in mechanical parallel between the primary transfer case shaft and the secondary output. The disc pack clutch includes a plurality of interleaved discs and an electromagnetic operator which effects compression of the disc pack to transfer torque from the primary transfer case output shaft to a chain drive sprocket, through a chain, to a secondary output shaft. The cone clutch is disposed adjacent the disc pack and is also actuated by the electromagnetic operator. The cone clutch includes a conical drive member driven by the primary transfer case output shaft. A conical driven member provides torque to the drive chain and, in turn, to the secondary output shaft. Preferably, the driven cone member is integrally formed with the chain drive sprocket.

Abstract: A power transmitting assembly includes a first rotatable assembly, a second rotatable assembly having an axially movable rotating member, a camming assembly for moving the rotating member and an electromagnetic clutch for activating the camming assembly. The rotating member is moved between a first position where the first rotatable assembly operatively engages the second rotatable assembly and a second position where the first rotatable assembly is disengaged from the second rotatable assembly. The power transmitting assembly is shown in three forms--a locking hub assembly, a lockable differential assembly and axle assembly having an axle disconnect.

Abstract: A part time four wheel drive vehicle has an axle disconnect in its auxiliary drive axle. The axle disconnect has a clutch sleeve non-rotatably and translatably mounted on an inner axle shaft so that the clutch sleeve translates between a first position where clutch teeth of the clutch sleeve engage clutch teeth of an outer axle shaft and a second position where the clutch teeth disengage. The clutch sleeve includes an integral annular piston that is part of a coaxial motor that shifts the clutch sleeve from one position to the other in conjunction with a return spring. The vacuum motor communicates with an external vacuum source and the axle disconnect includes a float valve for sealing a vacuum port of the vacuum motor to protect the external vacuum source against contamination if the vacuum motor is filled with lubricant in the axle housing leaking into the vacuum motor housing.