Abstract: A process is disclosed for selectively carburizing (tailored carburizing) a steel gear or similar ferrous metal object. The process of the present invention includes two similar but separate methods. The first method includes the steps of: first, masking the roots of the gear with an appropriate masking material, and conducting a first carburizing operation of the gear. Then, the masking material is removed from the gear roots and a second carburizing operation of the gear is conducted. The resulting carburized gear will have a lighter case with a lower carbon content in the root areas of the gear. The second method includes the steps of: masking the root areas of the gear with a coating material which would inhibit carbon diffusion in the root areas but not completely stop it. Then, carburizing the gear. Finally, the inhibiting agent is removed. The resulting carburized gear will have a lighter case with a lower carbon content in the root areas of the gear.

Abstract: The present invention is directed to an apparatus to regulate and control the temperature of a differential axle assembly. A heat pipe is inserted though the axle housing with a portion submersed in a reservoir portion of the axle lubricant. Cooling fins are preferably disposed on the heat pipe both in the submersed region of the heat pipe and a portion external the housing. A temperatures sensitive valve provided to inhibit flow of the axle lubricant between a reservoir and the remaining portion of the axle housing.

Abstract: A differential mechanism includes a clutch pack disposed outside said differential case and has a first set of clutch plates splined onto one of said axle shafts and a second set of clutch plates splined onto a housing sleeve, wherein the housing sleeve circumscribes said axle shaft. A control mechanism comprising an actuator actuates the clutch pack. The housing sleeve is splined to a trunnion portion of the differential case. This device simplifies and reduces the cost of the original assembly and/or the optional mounting of a controlling or limiting device associated with a differential mechanism whose output elements are connected to coaxial wheel shafts.

Abstract: An assembly by which to effect incremental adjustments to the end play, or preloading, to a bearing set. Relatively rotatable first and second thrust rings have contiguously juxtaposed and interacting ramp surfaces. Interposed between the first and second thrust rings is an indexing spring that provides incremental adjustment of the first thrust ring with respect to the second thrust ring. A plurality of indexing pawls formed on the indexing spring interacts with a plurality of indexing teeth formed on one of the thrust rings. The second thrust ring is selectively rotatable with respect to the first thrust ring to effect axial translation of the first thrust ring by virtue of the interaction between said opposed, contiguously juxtaposed ramp surfaces. The indexing pawls preclude reverse relative rotation of the thrust plates.

Abstract: Limited slip motor vehicle differential assemblies having a suitable high-shear strength, non-hardening, material which selectively resists slip or differentiation between the axle shafts and the differential housing, between the differential side gears and the differential housing, and/or between the differential side gears and the differential pinion gears when slip or differentiation occurs between two motor vehicle wheels mounted on the same axle. Such an arrangement provides some level of torque to each motor vehicle wheel at all times. The amount of resistance to slip or differentiation between the two motor vehicle wheels can be adjusted as desired by selecting an appropriate high-shear strength, non-hardening, material to provide the desired level of resistance to slip or differentiation between the two motor vehicle wheels in the motor vehicle differential assembly.

Abstract: Interconnected vents for a motor vehicle axle assembly, transmission or transfer case which interconnects multiple vents at different locations together with another vent positioned at the highest point the lubricant travels. This allows the lubricant to flow out of one vent and return to the other vent without leaking onto the ground. Such an interconnected vent arrangement will minimize the extent of external lubricant leakage due to such factors as foaming of the lubricant, air entrapment in the lubricant, volumetric expansion of the lubricant due to elevated operating temperatures, pumping or splashing of the lubricant by internal rotating or moving parts, flow of the lubricant due to tilting of the motor vehicle, and thus the motor vehicle axle assembly, transmission and transfer case, and/or acceleration or deceleration of the motor vehicle.

Abstract: Two-piece friction welded motor vehicle axle shaft which includes an axle portion which is frictionally welded to a flange portion. The flange portion is preferably fabricated from a relatively high carbon steel material, such as SAE 1050 Mod (Mn 0.80-1.10%), to satisfy the hardness requirement for the bearing race and the axle portion is preferably fabricated from a steel barstock material, such as SAE 1038, SAE 1040 or SAE 8630, having a somewhat lower carbon content to maximize its strength and ductility. The friction weld is preferably positioned inboard of the bearing race and, once welded, the two-piece motor vehicle axle shaft is machined to part profile, heat treated and then machined to final print dimensions.

Abstract: A limited slip planet gear for a motor vehicle differential assembly which uses a segmented planet gear having a plurality of fixed plates positioned between a corresponding plurality of planet gear segments. The plurality of fixed plates are preferably keyed to a planet gear pin and the plurality of fixed plates and the corresponding plurality of planet gear segments are compressed using a resilient compression member, for example, one or more belleville type springs or one or more leaf springs to provide limited slip capability to the motor vehicle differential assembly.

Abstract: A locking washer arrangement which includes two (2) washer members fabricated from a hardened steel material, a thicker one on the bottom and a thinner one on the top. The top surface of the top washer member and the bottom surface of the bottom washer member preferably have a relatively high coefficient of friction and may be grooved, embossed or otherwise roughened so they will grip the surfaces they come into contact with while the bottom surface of the top washer member and the top surface of the bottom washer member have a relatively low coefficient of friction to facilitate relative movement therebetween. Relatively long flexible tabs project radially outward from the periphery of the top washer member and distal ends are bent downwardly to engage and interlock between corresponding relatively short stiff tabs projecting radially outward from the periphery of the bottom washer member.

Abstract: A drive axle shaft for use in a full floating axle assembly includes a spline formed at an inner end thereof and a flange formed at an outer end thereof. A majority of the shaft body between the spline and the flange is of an increased diameter which is slightly smaller than the inner diameter of a reduced inner diameter portion of an axle housing through which the drive axle shaft extends. A pair of tapered portions form the transition between the increased diameter portion and the shaft ends to provide an axle shaft of increased torsional yield strength and torsional fatigue life.

Abstract: Initially, an uncut gear blank is softened by a heat treatment process to provide a relatively soft level of hardness throughout. Then, the softened gear blank is machined so as to form a plurality of teeth about the circumference thereof. The relatively soft machined gear is next subjected to a prehardening process, wherein the surfaces of the teeth and the outer region of the core are hardened to a predetermined intermediate level of hardness. Finally, the prehardened gear is subjected to a contour hardening process such that the surfaces of the gear teeth are further significantly hardened. The outer region of the core of the gear remains at the intermediate hardness level, while the inner region of the core remains at the relatively soft level.