Abstract: A differential carrier and ring gear assembly for a vehicle is provided. The assembly comprises a differential carrier, a ring gear, and a weld nugget. The differential carrier comprises an outer surface including a first contact face having a weld end extending to a root end. The first contact face has a first slot formed on a first radial portion thereof. The ring gear is disposed about the differential carrier and comprises an inner side having an inner surface. The inner side has a stop flange abutting the root end. The inner surface comprises a second contact face disposed on the first contact face such that the root end is in abutment with the second end. The first and second hollow channels define a pocket therebetween and the first slot defines a first vent hole for venting. The weld nugget is disposed between the first and second contact faces.

Abstract: A differential housing includes a body including an outer surface. The body has a first end, a second end, and an intermediate portion extending therebetween. A ring gear support member extends outwardly of the body at the second end. A ring gear support surface forms a first section of the intermediate portion. The ring gear support surface defines a first outer diameter of the intermediate portion. A ring gear is mounted to the outer surface of the body. The ring gear includes an inner annular surface having a first region defining a first inner diameter and a second region defining a second inner diameter. The first region includes a sawtooth profile to establish a desired alignment of the ring gear and the body and the second region facilitating an interference fit with the ring gear support surface.

Abstract: A differential barrel includes a body having a first end, a second end, and an intermediate portion extending therebetween. A ring gear support member extends outwardly at the second end. A ring gear support surface forms a first section of the intermediate portion. The ring gear support surface defines a first outer diameter of the intermediate portion. A ring gear alignment surface forms a second section of the intermediate portion. The ring gear alignment surface defines a second outer diameter of the intermediate portion. A ring gear is mounted to the outer surface of the body and includes an inner annular surface including a first region defining a first inner diameter and a second region defining a second inner diameter. The first region establishes an interference fit with the ring gear support surface. The second inner diameter is no more than about 0.05-inches (1.27-mm) greater than the second outer diameter.

Abstract: A differential housing includes a body including an outer surface. The body has a first end, a second end, and an intermediate portion extending therebetween. A ring gear support member extends outwardly of the body at the second end. A ring gear support surface forms a first section of the intermediate portion. The ring gear support surface defines a first outer diameter of the intermediate portion. A ring gear is mounted to the outer surface of the body. The ring gear includes an inner annular surface having a first region defining a first inner diameter and a second region defining a second inner diameter. The first region includes a sawtooth profile to establish a desired alignment of the ring gear and the body and the second region facilitating an interference fit with the ring gear support surface.

Abstract: A differential barrel includes a body having a first end, a second end, and an intermediate portion extending therebetween. A ring gear support member extends outwardly at the second end. A ring gear support surface forms a first section of the intermediate portion. The ring gear support surface defines a first outer diameter of the intermediate portion. A ring gear alignment surface forms a second section of the intermediate portion. The ring gear alignment surface defines a second outer diameter of the intermediate portion. A ring gear is mounted to the outer surface of the body and includes an inner annular surface including a first region defining a first inner diameter and a second region defining a second inner diameter. The first region establishes an interference fit with the ring gear support surface. The second inner diameter is no more than about 0.05-inches (1.27-mm) greater than the second outer diameter.