Abstract: A transfer case includes a clutch assembly having both a disc pack clutch and cone clutch disposed in mechanical parallel between the main transfer case shaft and secondary output shaft. The disc pack clutch includes a plurality of interleaved discs and an electromagnetic operator which effects compression of the clutch pack to transfer torque from the main transfer case shaft to a chain drive sprocket, through a chain, to the secondary output shaft. The cone clutch is disposed adjacent the disc pack and is also actuated by the electromagnetic operator. One of the cone clutch elements is driven by the main transfer case shaft and the other cone clutch element provides power to the drive chain and, in turn, to the secondary output shaft. Preferably, the other cone clutch element is integrally formed with the chain drive sprocket.

Abstract: A transfer case includes a clutch assembly having a disc pack clutch, a cone clutch and a lockup hub or collar. All three clutch components are disposed in mechanical parallel between the primary transfer case shaft and the secondary output. The disc pack clutch includes a plurality of interleaved discs and an electromagnetic operator which effects compression of the disc pack to transfer torque from the primary transfer case output shaft to a chain drive sprocket, through a chain, to a secondary output shaft. The cone clutch is disposed adjacent the disc pack and is also actuated by the electromagnetic operator. The cone clutch includes a conical drive member driven by the primary transfer case output shaft. A conical driven member provides torque to the drive chain and, in turn, to the secondary output shaft. Preferably, the driven cone member is integrally formed with the chain drive sprocket.

Abstract: A part time four wheel drive vehicle has an axle disconnect in its auxiliary drive axle. The axle disconnect has a clutch sleeve non-rotatably and translatably mounted on an inner axle shaft so that the clutch sleeve translates between a first position where clutch teeth of the clutch sleeve engage clutch teeth of an outer axle shaft and a second position where the clutch teeth disengage. The clutch sleeve includes an integral annular piston that is part of a coaxial motor that shifts the clutch sleeve from one position to the other in conjunction with a return spring. The vacuum motor communicates with an external vacuum source and the axle disconnect includes a float valve for sealing a vacuum port of the vacuum motor to protect the external vacuum source against contamination if the vacuum motor is filled with lubricant in the axle housing leaking into the vacuum motor housing.

Abstract: An annular propeller shaft (10) for transmitting torque from an automotive ehicle transfer case to the rear axle of the vehicle, the propeller shaft having an internal spline (16) which receives an externally splined portion (18a) of a drive shaft (18) at its torque input end and which is adapted to receive an externally splined portion of a slip yoke of a universal joint at its torque output end. The torque input end and a major portion of the length of the propeller shaft are surrounded by an internally lubricated housing (12), and the drive shaft is rotatingly support with respect to the housing by a ball bearing (20). The propeller shaft is rotatingly sealed with respect to the housing by a seal (32) and is rotatingly supported with respect to the housing by a sealed for life, internally lubricated ball bearing (28) which is positioned outboard of the seal. The outboard ball bearing is protected from contamination from external debris by an annular sheet metal guard housing.