Abstract: A transfer case (30) and a method of assembly in an all-wheel drive vehicle can include a range shifting assembly (60) for shifting between a low-range and high-range drive mode, a normally disengaged clutch assembly (80) for transferring drive torque to a first and second driveline, a clutch actuator (88), and an actuating gear (48). The clutch actuator (88) can be moveable between an expanded position and a contracted position and engageable with the clutch assembly (80) for engaging the clutch assembly (80) when in the expanded position. The actuating gear (48) can be reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator (88) between the contracted and expanded position for actuating the clutch assembly (80) and for shifting the range shifting assembly (60) between a low-range drive mode and a high-range mode when the clutch assembly (80) is in the disengaged position.

Abstract: A transfer case (30) and a method of assembly in an all-wheel drive vehicle can include a range shifting assembly (60) for shifting between a low-range and high-range drive mode, a normally disengaged clutch assembly (80) for transferring drive torque to a first and second driveline, a clutch actuator (88), and an actuating gear (48). The clutch actuator (88) can be moveable between an expanded position and a contracted position and engageable with the clutch assembly (80) for engaging the clutch assembly (80) when in the expanded position. The actuating gear (48) can be reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator (88) between the contracted and expanded position for actuating the clutch assembly (80) and for shifting the range shifting assembly (60) between a low-range drive mode and a high-range mode when the clutch assembly (80) is in the disengaged position.

Abstract: A transfer case (21, 330) and a method of assembly can include an input shaft (15) and output shafts (14, 16), a mode clutch (30) for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (56, 380, 480), a planetary gear assembly (20) for providing a different drive ratio between the input shaft (15) and the output shaft (14), a range shift mechanism (50, 360, 460), and a synchronizer (40, 340) for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear (24) can be connected to the planetary gear assembly (20) during the high-range and low-range drive mode. The mode shift mechanism (56) and the range shift mechanism (50) can be electro-mechanically actuated by a reversible rotatable actuating gear (348, 448) interposed between an expandable clutch actuator (388, 488) and a rotatable barrel cam (359, 459).

Abstract: A transfer case (21, 330) and a method of assembly can include an input shaft (15) and output shafts (14, 16), a mode clutch (30) for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (56, 380, 480), a planetary gear assembly (20) for providing a different drive ratio between the input shaft (15) and the output shaft (14), a range shift mechanism (50, 360, 460), and a synchronizer (40, 340) for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear (24) can be connected to the planetary gear assembly (20) during the high-range and low-range drive mode. The mode shift mechanism (56) and the range shift mechanism (50) can be electro-mechanically actuated by a reversible rotatable actuating gear (348, 448) interposed between an expandable clutch actuator (388, 488) and a rotatable barrel cam (359, 459).