Abstract: An improved twin clutch, two-speed disconnect secondary drive unit, which may be configured as a rear drive unit (RDU) for an all wheel drive vehicle is provided. The RDU is driven through an input shaft, which is connected to a vehicle drive source such as a motor, and includes a twin clutch assembly, which is connected to the drive shaft and is selectively actuated to drive left and right main shafts, which drive respective wheels of the vehicle. The RDU further includes a modular a shift assembly mountable to one or both of said main shafts to drive output shafts, wherein each shift assembly is selectively operable between the hi-range and lo-range modes to shift driving operation of the output shafts between hi-speed and lo-speed operation. The shift assembly may be controlled by improved mono-stable or bi-stable actuators.

Abstract: An improved twin clutch, two-speed disconnect secondary drive unit, which may be configured as a rear drive unit (RDU) for an all wheel drive vehicle is provided. The RDU is driven through an input shaft, which is connected to a vehicle drive source such as a motor, and includes a twin clutch assembly, which is connected to the drive shaft and is selectively actuated to drive left and right main shafts, which drive respective wheels of the vehicle. The RDU further includes a modular a shift assembly mountable to one or both of said main shafts to drive output shafts, wherein each shift assembly is selectively operable between the hi-range and lo-range modes to shift driving operation of the output shafts between hi-speed and lo-speed operation. The shift assembly may be controlled by improved mono-stable or bi-stable actuators.

Abstract: An improved differential for a vehicle is provided which includes a disconnect assembly engaged between a ring gear and pinion gears and/or a gear nest associated with the pinion gears, wherein the disconnect assembly is able to disconnect torsional loading of torque between the ring gear and the pinon gears of the differential. The disconnect assembly selectively connects and disconnects the ring gear and pinon gears by preferably disconnecting from the gear nest disposed therebetween. Disconnection of the ring gear and pinion gears allows the ring gear, differential housing, bearings, and rest of the gear box to stop spinning while the wheels of the vehicle are spinning. The differential pinion gears are mechanically connected to the gear nest such that torque can be transferred from the differential gear nest to the differential pinion gears and then to the differential side gears.

Abstract: A secondary drive unit (SDU) for the secondary axis of an all wheel drive vehicle consists of an SDU housing defining a first section for receiving a main shaft which is connected to a drive source and a second section for enclosing a twin clutch assembly. The twin clutch assembly has a common clutch housing connected to the main shaft, a left clutch for selectively connecting a left output shaft and the clutch housing, a right clutch for selectively connecting a right output shaft and the clutch housing, and a rigid center plate separating the left and right clutches. The twin clutch assembly may be activated by a dual action piston assembly to decrease all wheel drive synchronization and connection response times.

Abstract: An improved differential for a vehicle is provided which includes a disconnect assembly engaged between a ring gear and pinion gears and/or a gear nest associated with the pinion gears, wherein the disconnect assembly is able to disconnect torsional loading of torque between the ring gear and the pinon gears of the differential. The disconnect assembly selectively connects and disconnects the ring gear and pinon gears by preferably disconnecting from the gear nest disposed therebetween. Disconnection of the ring gear and pinion gears allows the ring gear, differential housing, bearings, and rest of the gear box to stop spinning while the wheels of the vehicle are spinning. The differential pinion gears are mechanically connected to the gear nest such that torque can be transferred from the differential gear nest to the differential pinion gears and then to the differential side gears.

Abstract: Systems, apparatus, and methods to control fluid associated with vehicle clutches are disclosed. A disclosed apparatus includes a drive unit assembly for a vehicle. The drive unit assembly includes a housing and a clutch in a cavity of the housing. Rotation of a drum of the clutch expels a fluid from the cavity. The apparatus also includes a vehicle controller configured to disengage the clutch via an actuator. Actuation of the actuator reduces a flow of the fluid into the cavity. The vehicle controller is also configured to maintain engagement of a vehicle transfer device operatively coupled between a vehicle transmission and the drum such that the drum continues to rotate for a time interval during which the clutch is disengaged.

Abstract: Piston apparatus for use with vehicle clutches are disclosed. A disclosed drive unit assembly for a vehicle includes a housing defining a first cavity and a second cavity fluidly coupled together. The drive unit assembly also includes a clutch positioned in the first cavity. Rotation of the clutch conveys a fluid from the first cavity to the second cavity. The drive unit assembly also includes a port extending from the second cavity to the first cavity to receive the fluid. The drive unit assembly also includes a piston positioned in the first cavity proximate to the port and configured to operate the clutch. Movement of the piston relative to the port controls a flow of the fluid through the port from the second cavity to the first cavity.

Abstract: Systems, apparatus, and methods to control fluid associated with vehicle clutches are disclosed. A disclosed apparatus includes a drive unit assembly for a vehicle. The drive unit assembly includes a housing and a clutch in a cavity of the housing. Rotation of a drum of the clutch expels a fluid from the cavity. The apparatus also includes a vehicle controller configured to disengage the clutch via an actuator. Actuation of the actuator reduces a flow of the fluid into the cavity.

Abstract: Piston apparatus for use with vehicle clutches are disclosed. A disclosed drive unit assembly for a vehicle includes a housing defining a first cavity and a second cavity fluidly coupled together. The drive unit assembly also includes a clutch positioned in the first cavity. Rotation of the clutch conveys a fluid from the first cavity to the second cavity. The drive unit assembly also includes a port extending from the second cavity to the first cavity to receive the fluid. The drive unit assembly also includes a piston positioned in the first cavity proximate to the port and configured to operate the clutch. Movement of the piston relative to the port controls a flow of the fluid through the port from the second cavity to the first cavity.

Abstract: A secondary drive unit (SDU) for the secondary axis of an all wheel drive vehicle consists of an SDU housing defining a first section for receiving a main shaft which is connected to a drive source and a second section for enclosing a twin clutch assembly. The twin clutch assembly has a common clutch housing connected to the main shaft, a left clutch for selectively connecting a left output shaft and the clutch housing, a right clutch for selectively connecting a right output shaft and the clutch housing, and a rigid center plate separating the left and right clutches. The twin clutch assembly may be activated by a dual action piston assembly to decrease all wheel drive synchronization and connection response times.