Abstract: A drive shaft assembly for a vehicle includes a first tubular member and a second tubular member that is received by the first tubular member defining a coaxial relationship. The first tubular member defines a plurality of protuberances with each of the protuberances defining a side wall and the second tubular member defines a plurality of apertures with each of the apertures defined by a flange circumscribing the aperture and extending radially inwardly of second tubular member. Each aperture receives a protuberance so that the protuberance abuts the sidewalls of the aperture affixing the first tubular member to said second tubular member in a substantially fixed circumferential orientation.

Abstract: A method of manufacturing an annular transmission component for a vehicle includes providing a tube defining an annular wall having a predetermined diameter. The tube is cut to a form a tube blank having a first end and a second end. The tube blank placed into a forming machine and the first end of the tube blank is rolled relative to the second end of the tube blank forming an annular U-shaped channel defined between the first and the second end.

Abstract: A method of forming a shaft for transferring force from a driving element to a driven element makes use of a tube. The tube is deformed to define distal ends of said shaft. At least one of the distal ends of the tube is trimmed to define a yoke for engaging one of the driving element or the driven element, with the yoke being integrally formed with the shaft.

Abstract: A method of forming a joint for interconnecting adjacent elements comprises providing a first element defining at least one aperture extending from a first edge to a second edge through a thickness of the first element. The method further comprises mating a second element to the first element with the second element overlaying the at least one aperture of the first element at the second edge thereof such that the second element extends through the at least one aperture perpendicular to the first element with an excess portion of the second element extending beyond the first edge of the first element. Finally, the method comprises compressing the excess portion of the second element such that the second element is continuous across the at least one aperture and adjacent the first and second edges of the first element, thereby interlocking the first and second elements and forming the joint.

Abstract: A method of manufacturing an impeller and turbine assembly of a transmission includes providing an impeller housing and a turbine housing. An impeller blade defining an impeller receptor and a turbine blade defining a turbine receptor are provided. The impeller blade is mated to the impeller housing by deforming a portion of said impeller housing into the impeller receptor. The turbine blade is mated to the turbine housing by deforming a portion of the turbine housing into the turbine receptor. In this manner, the impeller blade is secured to the impeller housing and the turbine blade is secured to the turbine housing.

Abstract: A drive shaft assembly for a vehicle includes a first tubular member and a second tubular member that is received by the first tubular member defining a coaxial relationship. The first tubular member defines a plurality of protuberances with each of the protuberances defining a side wall and the second tubular member defines a plurality of apertures with each of the apertures defined by a flange circumscribing the aperture and extending radially inwardly of second tubular member. Each aperture receives a protuberance so that the protuberance abuts the sidewalls of the aperture affixing the first tubular member to said second tubular member in a substantially fixed circumferential orientation.

Abstract: A method of manufacturing an impeller and turbine assembly of a transmission includes providing an impeller housing and a turbine housing. An impeller blade defining an impeller receptor and a turbine blade defining a turbine receptor are provided. The impeller blade is mated to the impeller housing by deforming a portion of said impeller housing into the impeller receptor. The turbine blade is mated to the turbine housing by deforming a portion of the turbine housing into the turbine receptor. In this manner, the impeller blade is secured to the impeller housing and the turbine blade is secured to the turbine housing.

Abstract: A method of forming a joint for interconnecting adjacent elements comprises providing a first element defining at least one aperture extending from a first edge to a second edge through a thickness of the first element. The method further comprises mating a second element to the first element with the second element overlaying the at least one aperture of the first element at the second edge thereof such that the second element extends through the at least one aperture perpendicular to the first element with an excess portion of the second element extending beyond the first edge of the first element. Finally, the method comprises compressing the excess portion of the second element such that the second element is continuous across the at least one aperture and adjacent the first and second edges of the first element, thereby interlocking the first and second elements and forming the joint.

Abstract: A method of forming a shaft for transferring force from a driving element to a driven element makes use of a tube. The tube is deformed to define distal ends of said shaft. At least one of the distal ends of the tube is trimmed to define a yoke for engaging one of the driving element or the driven element, with the yoke being integrally formed with the shaft.

Abstract: A torque transmitting assembly, such as a differential, including a tubular housing having a polygonal cross-section including a plurality of angularly related surfaces and a torque transmitting member within the housing having flat surfaces engaging the flat surfaces of the housing, such that torque is transmitted through the housing. In a differential, the torque transmitting member includes annular side gears having a plurality of annular teeth and annular pinion gears including gear teeth meshing with the gear teeth of the side gears.

Abstract: A method of forming a housing which includes roll forming a steel tube radially inwardly with a plurality of rollers each having a rolling axis parallel to the longitudinal axis of the tube, the rollers compressing the tube and forming reduced diameter portions and enlarged diameter portions. The method then includes cutting the tube perpendicular to the longitudinal axis generally midway through an enlarged diameter portion and a reduced diameter portion, forming a plurality of minor image preforms. Finally, the method includes cold working the preforms into the desired shape of the housing and increasing the strength of the steel at least 15% and forming a housing member having enlarged diameter open end and a reduced diameter open end.

Abstract: A clutch assembly including a housing having internal radial teeth including relatively sharp V-shaped crests and troughs and annular clutch plates having teeth of the same configuration, wherein the included angle between adjacent teeth is about 60°. The internal surface of the housing in the disclosed embodiment further includes generally straight segments between a plurality of adjacent teeth having a longitudinal oil slot. The radial teeth of the clutch plates are continuous to nest into the internal teeth of the housing and the relatively straight segments.

Abstract: A clutch assembly for a vehicle transmission includes a housing defined by a wall having an annular configuration circumscribing a clutch axis. The wall extends between an open end and a floor. The floor extends inwardly from the wall toward the clutch axis. A plurality of splines formed in the wall and each is spaced from the open end of the housing. A snap ring retains clutch plates in the housing. The open end of the wall is deformed inwardly toward the clutch axis defining a retainer for retaining the snap ring within the housing.

Abstract: A rotational assembly includes a mating surface and an interlocking surface disposed in driving engagement with a cooperable interlocking member of a driving mechanism. A plurality of receptors is defined in the mating surface. A bearing element is received in each of the plurality of receptors for reducing frictional interaction between the mating surface of the rotational assembly and a complementary mating surface of an interacting component. A retainer is defined in the mating surface at each of the receptors providing rotational retention of each of the bearing elements within its corresponding receptor.

Abstract: A clutch assembly for a vehicle transmission includes a housing defined by a wall having an annular configuration circumscribing a clutch axis. The wall extends between an open end and a floor. The floor extends inwardly from the wall toward the clutch axis. A plurality of splines formed in the wall and each is spaced from the open end of the housing. A snap ring retains clutch plates in the housing. The open end of the wall is deformed inwardly toward the clutch axis defining a retainer for retaining the snap ring within the housing.

Abstract: A method of making a universal joint from a tube, including forming a plurality of pairs of coaxially aligned holes at longitudinally spaced locations in the tube, cutting the tube along a curvilinear cutting path around the holes forming a pair of projecting arms and U-shaped recesses between the arms forming a plurality of yokes and pivotally interconnecting the yokes using a pivot member received in the holes of adjacent yokes.

Abstract: A clutch assembly includes a housing defining an axis. A plurality of plates disposed within the housing are in driving engagement with the housing around the axis. The housing defines a housing wall circumscribing the axis and having a sinusoidal configuration including a wall crest and a wall trough. The wall crest and the wall trough are substantially parallel to the axis defined by the housing. The plates have teeth complimentary of the sinusoidal configuration of the housing wall for engaging the housing wall enabling the driving engagement between the housing wall and the plates.

Abstract: A housing for use with a clutch assembly includes an annular wall disposed around an axis and extending between an open end of the housing and a floor of the housing with the floor extending toward the axis. A plurality of splines are spaced around the annular wall and extends between the open end and the floor. The splines define a work surface for engaging teeth of a clutch plate with the work surface being fractured from the annular wall providing a substantially normal relationship to the annular wall.

Abstract: A rotational assembly includes a mating surface and an interlocking surface disposed in driving engagement with a cooperable interlocking member of a driving mechanism. A plurality of receptors is defined in the mating surface. A bearing element is received in each of the plurality of receptors for reducing frictional interaction between the mating surface of the rotational assembly and a complementary mating surface of an interacting component. A retainer is defined in the mating surface at each of the receptors providing rotational retention of each of the bearing elements within its corresponding receptor.

Abstract: A rotational assembly includes a mating surface and an interlocking surface disposed in driving engagement with a cooperable interlocking member of a driving mechanism. A plurality of receptors is defined in the mating surface. A bearing element is received in each of the plurality of receptors for reducing frictional interaction between the mating surface of the rotational assembly and a complimentary mating surface of an interacting component. A retainer is defined in the mating surface at each of the receptors providing rotational retention of each of the bearing elements within its corresponding receptor.