Abstract: An actuator that includes a housing, first and second drive portions, a rotary-to-linear converter and an output member. The housing defines a first housing part and a second housing part that is segregated from first housing part by a housing wall. The first drive portion is housed in the first housing part and has a source of rotary power and an intermediate output that is driven by the source of rotary power. The second drive portion is housed in the second housing part and has an intermediate input and a transmission. The intermediate input receives rotary power from the intermediate output and transmits rotary power to the transmission. The intermediate input does not physically contact the intermediate output and the housing wall is disposed between the intermediate output and the intermediate input. The rotary-to-linear converter driven by the transmission. The output member translated along an axis by the rotary-to-linear converter.

Abstract: A disconnectable all-wheel drive vehicle driveline having a primary driveline, a power take-off unit (PTU), a secondary driveline, a hydraulic pump and a driveline actuator. The PTU has a PTU input member, which is driven by the primary driveline, a PTU output member and a first coupling that selectively couples the PTU input and output members. The secondary driveline includes a second coupling that selectively inhibits power transmission through the secondary driveline. The hydraulic pump is configured to operate the first coupling but is powered by a synchronization event in which the second coupling is engaged so as to back drive the PTU output member.

Abstract: A power transmitting component with a housing, a shaft and a seal. The housing has a wall member, a shaft bore, and a shield wall. The shaft bore is formed through the wall member. The shield wall is coupled to and extends outwardly from the wall member. The shield wall is formed about the shaft bore and defines a drain spout. The shaft is received through the shaft bore. The seal is received in the shaft bore and sealingly engages the housing and the shaft. The drain spout is configured to drain liquid from a space that is radially inward of the shield wall when the power transmitting component is disposed in a predetermined orientation.

Abstract: A power transmitting component with a housing, a shaft and a seal. The housing has a wall member, a shaft bore, and a shield wall. The shaft bore is formed through the wall member. The shield wall is coupled to and extends outwardly from the wall member. The shield wall is formed about the shaft bore and defines a drain spout. The shaft is received through the shaft bore. The seal is received in the shaft bore and sealingly engages the housing and the shaft. The drain spout is configured to drain liquid from a space that is radially inward of the shield wall when the power transmitting component is disposed in a predetermined orientation.

Abstract: A transfer case for use in motor vehicles for transferring drive torque from a powertrain to first and second drivelines includes a first output shaft adapted to transmit drive torque from the powertrain to the first driveline. The second output shaft is adapted to transmit drive torque to a second driveline. The transfer case includes a first spiral bevel gear set driven by the first output shaft and a second spiral bevel gear set driven by the first spiral bevel gear set and driving the second output shaft.

Abstract: A wheel speed measurement system for a drive axle is provided within a differential assembly. The system includes a differential side bearing adjustment ring configured for adjusting the position of a differential carrier bearing assembly. A tone ring is provided having an inner bore to accommodate a coaxial axle shaft. A retainer ring member is snap-fit between the differential side bearing adjustment ring and the tone ring, permitting relative rotation of the tone ring. Sensors are provided in sensor mounts integrally formed on an exterior of a differential assembly housing.

Abstract: A fastener with a threaded nut, a clip, a first engagement feature and a second engagement feature. The nut has front and rear surfaces and a first lock structure that is disposed between the front and rear surfaces. The clip has a body, which defines an aperture, a second lock structure and an engagement member. The second lock structure is coupled to the body and engages the first lock structure to axially retain the clip to the nut. The engagement member extends into the aperture in the body. The first engagement feature is coupled to either the nut or the clip and comprises at least one tooth. The second engagement feature is associated with the other one of the nut and the clip and is engaged with the first engagement feature to inhibit rotation between the nut and the clip.

Abstract: A torque transmitting component that includes a hollow adjuster that is employed to preload and/or position a bearing that supports a differential assembly relative to a housing. One of the housing and the adjuster includes a first engagement feature and the other one of the housing and the adjuster includes a second engagement feature. A retaining member is press-fit to the first engagement feature and is non-rotatably coupled to the second engagement feature to inhibit rotation of the adjuster relative to the housing. A method is also provided.

Abstract: A torque transmitting component that includes a hollow adjuster that is employed to preload and/or position a bearing that supports a differential assembly relative to a housing. One of the housing and the adjuster includes a first engagement feature and the other one of the housing and the adjuster includes a second engagement feature. A retaining member is press-fit to the first engagement feature and is non-rotatably coupled to the second engagement feature to inhibit rotation of the adjuster relative to the housing. A method is also provided.

Abstract: A method that includes positioning a differential assembly between a pair of journals in a differential housing, threading hollow adjusters into the journals, installing a retaining member over each of the hollow adjusters such that the retainer engages a non-circular feature on a respective one of the hollow adjusters, and pressing each of the retaining members into a counterbore formed on an assocated one of the journals such that the retaining members engage the differential housing in via an interference fit to inhibit relative rotation between the retaining members and the differential housing.

Abstract: A method that includes positioning a differential assembly between a pair of journals in a differential housing, threading hollow adjusters into the journals, installing a retaining member over each of the hollow adjusters such that the retainer engages a non-circular feature on a respective one of the hollow adjusters, and pressing each of the retaining members into a counterbore formed on an assocated one of the journals such that the retaining members engage the differential housing in via an interference fit to inhibit relative rotation between the retaining members and the differential housing.

Abstract: A wheel speed measurement system for a drive axle is provided within a differential assembly. The system includes a differential side bearing adjustment ring configured for adjusting the position of a differential carrier bearing assembly. A tone ring is provided having an inner bore to accommodate a coaxial axle shaft. A retainer ring member is snap-fit between the differential side bearing adjustment ring and the tone ring, permitting relative rotation of the tone ring. Sensors are provided in sensor mounts integrally formed on an exterior of a differential assembly housing.

Abstract: An axle assembly with an axle housing with a pair of bearing journals, a differential assembly disposed between the bearing journals, a pair of differential bearings and a pair of hollow adjusters that can be threaded into the bearing journals to preload the differential bearings and control gear lash between a pinion and a ring gear. Retaining members can be non-rotatably engage to the hollow adjusters and can be press-fit into counterbores in the outboard sides of the bearing journals. The axle housing can include an unitarily formed differential housing with a body and an axle tube structure, and a first axle tube that can be discretely formed and coupled to the body.

Abstract: A fastener with a threaded nut, a clip, a first engagement feature and a second engagement feature. The nut has front and rear surfaces and a first lock structure that is disposed between the front and rear surfaces. The clip has a body, which defines an aperture, a second lock structure and an engagement member. The second lock structure is coupled to the body and engages the first lock structure to axially retain the clip to the nut. The engagement member extends into the aperture in the body. The first engagement feature is coupled to either the nut or the clip and comprises at least one tooth. The second engagement feature is associated with the other one of the nut and the clip and is engaged with the first engagement feature to inhibit rotation between the nut and the clip.

Abstract: A transfer case for use in motor vehicles for transferring drive torque from a powertrain to first and second drivelines includes a first output shaft adapted to transmit drive torque from the powertrain to the first driveline. The second output shaft is adapted to transmit drive torque to a second driveline. The transfer case includes a first spiral bevel gear set driven by the first output shaft and a second spiral bevel gear set driven by the first spiral bevel gear set and driving the second output shaft.

Abstract: An axle assembly with an axle housing with a pair of bearing journals, a differential assembly disposed between the bearing journals, a pair of differential bearings and a pair of hollow adjusters that can be threaded into the bearing journals to preload the differential bearings and control gear lash between a pinion and a ring gear. Retaining members can be non-rotatably engage to the hollow adjusters and can be press-fit into counterbores in the outboard sides of the bearing journals. The axle housing can include an unitarily formed differential housing with a body and an axle tube structure, and a first axle tube that can be discretely formed and coupled to the body.

Abstract: An axle assembly with a cooling pump. The cooling pump includes a disk-shaped wheel with a plurality of radially-spaced ducts formed therein. The wheel is positioned in proximity to the axle assembly and rotated, allowing the ducts to draw air therethrough and direct the air to the axle assembly.

Abstract: A differential assembly includes a case, a gearset having a pair of pinion gears and a pair of side gears, and an electrically operable coupling including a magnetically responsive fluid. The coupling is operable to selectively interconnect one of the side gears to the case. In one instance, the present invention includes a rotor having a plurality of outwardly extending blades positioned in communication with a magneto-rheological fluid. An electromagnet is selectively actuated to change the viscosity of the magneto-rheological fluid. In this manner, the differential may function as an “open” differential, a “locked” differential or a differential accommodating a limited-slip condition.

Abstract: A differential system includes a case, a pair of pinion gears, a pair of side gears and an electrically operable coupling including a magnetically responsive fluid. The coupling selectively drivingly interconnects one of the side gears and the case. In one instance, the present invention includes a rotor having a plurality of outwardly extending blades positioned in communication with a magneto-rheological fluid. An electromagnet is selectively actuated to change the viscosity of the magneto-rheological fluid. In this manner, the differential may function as an “open” differential, a “locked” differential or a differential accommodating a limited-slip condition.

Abstract: An arrangement for securely retaining a cross pin within a differential assembly includes a cross pin having a groove positioned proximate a recess formed in a differential housing. The recess and the groove define a retention passageway at least partially filled with molten resin. Solidified resin material positioned within the retention passageway retains the cross pin in the differential housing. Another embodiment cross pin retention system includes a pair of locking clips coupled to the cross pin. Each of the pinion gears of the differential assembly is retained between one of the locking clips and the differential housing.