Abstract: A lubrication system of an axle assembly comprising a differential carrier rotatably supporting a differential case therewithin, an axle tube extending outwardly from the differential carrier, a bearing assembly for rotatably supporting the differential case within the differential carrier, and an annular drain-back baffle formed with a drain-back hole passing through the drain-back baffle and defining an oil delivery passage between the differential carrier and the axle tube. The drain-back baffle is selectively positioned within the axle assembly to provide changeable oil flow characteristics of the axle assembly. A method is provided for controlling flow of lubricant between a differential gear and an axle tube by selectively adjusting the position of the drain-back channel in order to provide the desired lubricant flow path.

Abstract: A rigid drive axle assembly includes a support beam member having a substantially flat central plate section, a differential assembly module secured to the central plate section through at least two threaded studs extending from the central plate section. The differential assembly module includes a differential carrier frame member having two bearing hubs receiving differential bearings. A method for verifying a predetermined bearing preload of the differential assembly module comprises the steps of preloading the differential bearings to the predetermined bearing preload, inserting mounting bores in the bearing hubs of the frame member onto the mounting studs, and determining that the differential bearings are properly preloaded if the mounting studs are received in the mounting bores in the differential carrier frame member without substantial resistance, or determining that the differential bearings are not properly preloaded if the mounting studs may not be received in the mounting bores easily.

Abstract: A drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central plate section and two opposite arm sections, a differential assembly module secured to the central plate section and enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central plate section. A method for assembling the drive axle assembly comprises the steps of securing the front cover to a front mounting surface of the support beam member, fastening the differential assembly module to the central plate section of the support beam member, and fastening the rear cover to the rear mounting surface of the support beam member.

Abstract: A drive axle assembly for a motor vehicle comprises a support beam member, a differential assembly module secured to the support beam member and a cover member fastened to the support beam member to cover at least a portion the differential assembly module. The cover member includes two spaced access openings with adjustable sealing flange devices for sealing an interior cavity within the cover member between the access openings and corresponding axle shaft members. The sealing flange device is positionally adjustable relative to the cover member. A method for adjusting position of the sealing flange device relative to the cover member comprises the steps of securing the cover member to the axle support member, mounting the sealing flange device to the cover member, adjusting the position of the sealing flange device relative to the cover member and securing the sealing flange device to the cover member.

Abstract: A wheel end assembly in a steering beam axle for use in a motor vehicle. The wheel end assembly comprises a tube yoke attached to an axle tube defining an axle centerline, a steering knuckle defining a steering knuckle centerline, a driving axle shaft rotatably disposed in the axle tube, a live spindle rotatably supported by the steering knuckle, a stub shaft extending through the live spindle and rotatably coupled thereto, and a universal joint connecting the driving axle shaft and the stub shaft. The steering knuckle is pivotally coupled to the tube yoke through a pair of vertically spaced swivel joints defining a steering axis. The wheel end assembly further includes a knuckle centering adjuster for adjusting the knuckle centerline by selectively moving said steering knuckle relative to said tube yoke along said steering axis in order to align the knuckle centerline to the axle centerline.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.

Abstract: An adjustable mounting assembly for a steerable wheel assembly. A pin member is horizontally movably disposed within a slot formed in the lower arm of a yoke assembly. A ball joint forging is adjustably secured to the lower arm. The pin member extends between the lower arm and a ball joint forging to facilitate selective adjustment therebetween. A pair of set screws are secured to the lower arm to engage opposite sides of the pin member to selectively move the pin member within the slot. By simply rotating the set screws, the pin member is horizontally adjusted to selectively move the ball joint forging in a horizontal direction to adjust the caster of the wheel assembly. Horizontal slots are formed in the lower arm to align with boltholes formed in the ball joint forging to allow the forging to be bolted to the lower arm over a range of horizontal positions.

Abstract: A speed-sensing system for a differential assembly, wherein a tone ring positioned on the ring gear flange is eliminated and the speed-sensing equipment is specially placed in the form of a thrust washer and/or slinger with a tone sensing ring disposed between the yoke and the inner race of the pinion shaft to avoid bending distortions of the ring gear under various dynamic load conditions.

Abstract: A method for controlling an axle shaft endplay in a differential assembly is disclosed. The desired axle shaft endplay is determined by a differential manufacturer based on the specific operating conditions of the differential assembly. In accordance with the endplay controlling method of the present invention, first the differential is partially assembled by mounting side gears and a differential pinion shaft carrying pinions in a differential case. Then, the manufacturer determines a thickness of an axle shaft-retaining ring that would provide the desired endplay. The manufacturer is provided with an endplay controlling kit of a plurality of the retaining rings of assorted thickness. The appropriate retaining ring is selected from the kit having the thickness as determined in the previous step. Next, axle shafts are inserted into the differential case through the side gears, and the selected retaining ring is mounted to the axle shafts. After this step, the assembly of the differential is completed.

Abstract: A limited slip differential for vehicular applications that eliminates chattering noise from the differential while maintaining seal integrity. This is accomplished by the use of a differential casing that includes at least a pair of fluid seals isolating a first chamber for bathing the respective differential components in a fluid lubricant appropriate to the contained components. A fluid lubricant, such as one containing a friction modifier is particularly suitable for the array of friction plates and pads of a disk pack, but can be detrimental to sealing elements, such as about the pinion gear. The separate chambers allows for the use of different fluid lubricants.

Abstract: In a differential/mechanism for transmitting power from a drive shaft to the axle shafts of a motor vehicle, an axle shaft end play adjuster is threadingly disposed at the end of the axle shaft adjacent the differential pinion shaft. The end play adjuster limits the range of axially inward movement of the axle shaft. A axle shaft end play adjuster assembly includes a shaft supported for rotation about a longitudinal axis having a threaded portion located near an axial end of the shaft to support a washer and a threader adjustment member threadingly engaging the end of the axle shaft adjacent the differential pinion shaft. The adjustment members threaded onto the interior axial end of the axle shaft may respectively engage the associated side gear through a splined interface.

Abstract: The device for adjusting an endplay of an axle shaft in a differential assembly includes an axle shaft supported in a differential case for rotation about a longitudinal axis, and an endplay adjustment member threadedly mounted on a terminal shoulder provided at an inboard end of the axle shaft. The axle shaft has external splines adapted to mate with internal splines of a differential side gear and an annular groove located adjacent to the terminal shoulder. The annular groove receives a retainer ring provided to limit an axial displacement of the axle shaft in an outboard direction. The endplay adjustment member is selectively positionable on the terminal shoulder along the axial direction of the axle shaft to variably limit an axial movement of the retainer ring within the annular groove, thus adjusting the axle shaft endplay.

Abstract: An axle assembly employs a simple adjustable connection between the differential case and the housing to adjust the position of the ring gear relative to the pinion gear. A pair of adjustment collars facilitates positioning the differential case to selectively position the ring gear relative to the pinion gear of an input shaft. The adjustment collars threadingly engage the differential case. Bearings are disposed between the adjustment collars and the housing. The adjustment collars are rotated to position the differential case together with the ring gear. The adjustment collars are also provided to adjust the preload of the bearings. A locking collar is employed to lock the adjustment collars once the differential case and ring gear are properly positioned. In an alternate embodiment a single adjustment collar is employed. Shims and spacers are utilized to position the differential case and ring gear and the adjustment collar used to adjust the preload of the bearings.

Abstract: A differential assembly having a limited slip device with a mechanism to adjust the preload of a clutch pack. The differential assembly includes a differential case with pinion and side gears disposed therein. The clutch pack is disposed between at least one of the side gears and the differential case to retard relative rotation there between. An adjustment collar is disposed between the clutch pack and the differential case to adjust the preload of the clutch pack. Elongated slots are formed through the differential case to provide external access to spanner slots formed in the adjustment collar. A tool may be inserted through the elongated slots to engage the spanner slots and selectively rotate the adjustment collar to adjust the preload.

Abstract: A novel arrangement of an electronically controlled limited slip differential assembly including a friction clutch assembly provided within a differential case for selectively restricting differential action. The friction clutch assembly is contained between a separation plate fixed to the differential case and axially spaced from a side gear, and a thrust collar splined to one of axle shafts and movable in axial direction in order to actuate the friction clutch assembly. The friction clutch assembly includes alternating inner friction plates splined to the thrust collar, and outer friction plates non-rotatably coupled to the differential case. The friction clutch assembly is actuated by a selectively controllable actuator including an electrical motor, a reduction gearing and a ball-and-ramp actuator adapted to axially displace the thrust collar in response to rotation of the electrical motor. The differential assembly provides both limited slip and open differential capabilities.

Abstract: The drive axles of a motor vehicle differential assembly are secured within the central bores provided in the side gears of the differential assembly by a pair of arcuate retaining element having a rounded cross section which preferably is a piece of bar stock bent to define a 180° half-ring element that is securely held between an arcuate groove formed along the circumference of the axle and a rounded abutment surface provided on the side gear. The arcuate groove and rounded abutment surface reduce stress risers and eliminate the counterbore typically provided in the side gear. Moreover, the pair of retaining elements maximizes the frictional contact by circumscribing the axle by approximately 360°.

Abstract: A limited slip differential assembly comprising a differential case and two side gears rotatably supported within the differential case. Each of the side gears provided with a pre-loaded clutch pack mounted on a hub portion of the side gear. In one embodiment, a lock ring is permanently pressed on the hub portion of the side gear adjacent a collar and the clutch pack for retaining the clutch pack in a predetermined pre-loaded condition. In a second embodiment, an adjustment collar is threaded onto the side gear and a thrust washer having a selected thickness maintains the pre-load condition. In both embodiment, a side gear/clutch pack assembly may be pre-assembled as a pre-loaded self-contained module before the various components of the differential assembly are assembled in the differential case.

Abstract: A pressure relief check valve for a hydraulically actuated clutch pack or limited slip device in a limited slip differential or torque coupling device. A ball seat is formed on the external surface of the differential case and is connected to a passageway leading to a limited slip device within the differential case to establish fluid communication there between. A ball rests on the valve seat and is retained thereon by a retainer and spring. The retainer is removable secured to the outer surface of the differential case and a coil spring is disposed between the ball and the retainer to bias the ball against the valve seat. When pressure within the differential case or limited slip device exceeds a predetermined pressure, the ball is lifted from the valve seat and fluid passes through the differential case to an exterior within the differential housing. When pressure in the differential case and limited slip device is less than the predetermined pressure, fluid is prevented from passing through the valve.

Abstract: A lubrication system of an axle assembly comprising a differential carrier, a side bearing assembly, an annular drain-back spacer provided therebetween, and a device for selectively positioning the drain-back spacer relative to the bearing assembly. The drain-back spacer is provided with a drain-back channel formed therethrough. A method is provided for controlling flow of lubricant between a differential gear and an axle tube by selectively adjusting the position of the drain-back channel in order to provide the desired lubricant flow path.