Abstract: A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.

Abstract: A number of variations may include a product comprising an output shaft having a radial flange comprising a plurality of teeth; a range shifter operatively connected to the output shaft constructed and arranged to selectively shift a vehicle between a low range, high range, and neutral mode; a mode shifter operatively connected to the output shaft constructed and arranged to shift the vehicle between a four-wheel and two-wheel drive mode; a dual drive gear operatively attached to the output shaft between the range shifter and the mode shifter constructed and arranged so that rotation of the dual drive gear drives the range shifter and the mode shifter; and at least one plunger radially displaced around the output shaft which is actuated by the dual drive gear to engage a slot between the plurality of teeth on the output shaft to prevent rotation of the shaft during a range shift.

Abstract: A product comprising: an axle shaft and an input shaft, wherein the axle shaft is coaxial with the input shaft; a clutch operatively connected to the axle shaft and the input shaft constructed and arranged to selectively couple and decouple the input shaft and the axle shaft; an actuator operatively connected to the clutch to drive the clutch; and a synchronizer operatively connected to the clutch to synchronize the coupling of the input shaft and the axle shaft.

Abstract: A number of variations may include a product comprising an axle shaft and an input shaft, wherein the axle shaft is coaxial with the input shaft; a clutch operatively connected to the axle shaft and the input shaft constructed and arranged to selectively couple and decouple the input shaft and the axle shaft; and a ring-shaped moving magnet actuator operatively connected to the clutch to drive the clutch.

Abstract: A transfer case (18) is disclosed. The transfer case (18) includes an input shaft (16) and a sun gear (56). The sun gear (56) includes a collar end (58) and a gear end (60) and at least a portion of the sun gear (56) circumscribes the input shaft (16). A hub (62) circumscribes the collar end (58) and the input shaft (16), and may be slidably move between a first position (64) and a second position (66) opposite the first position (64) along the input shaft (16) and the collar end (58). A plurality of planetary gears (70) is mounted in a carrier body (72) circumscribing the gear end (60), and the carrier body (72) is splined with the transfer case input shaft (16). A ring gear (78) circumscribes the plurality of planetary gears (70) mounted in the carrier body (72), and is integrally joined with an output shaft (20). The ring gear (78) is rotatable around the plurality of planetary gears (70).

Abstract: A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.

Abstract: A transfer case (18) is disclosed. The transfer case (18) includes an input shaft (16) and a sun gear (56). The sun gear (56) includes a collar end (58) and a gear end (60) and at least a portion of the sun gear (56) circumscribes the input shaft (16). A hub (62) circumscribes the collar end (58) and the input shaft (16), and may be slidably move between a first position (64) and a second position (66) opposite the first position (64) along the input shaft (16) and the collar end (58). A plurality of planetary gears (70) is mounted in a carrier body (72) circumscribing the gear end (60), and the carrier body (72) is splined with the transfer case input shaft (16). A ring gear (78) circumscribes the plurality of planetary gears (70) mounted in the carrier body (72), and is integrally joined with an output shaft (20). The ring gear (78) is rotatable around the plurality of planetary gears (70).

Abstract: A product comprising: an axle shaft and an input shaft, wherein the axle shaft is coaxial with the input shaft; a clutch operatively connected to the axle shaft and the input shaft constructed and arranged to selectively couple and decouple the input shaft and the axle shaft; an actuator operatively connected to the clutch to drive the clutch; and a synchronizer operatively connected to the clutch to synchronize the coupling of the input shaft and the axle shaft.

Abstract: A number of variations may include a product comprising an output shaft having a radial flange comprising a plurality of teeth; a range shifter operatively connected to the output shaft constructed and arranged to selectively shift a vehicle between a low range, high range, and neutral mode; a mode shifter operatively connected to the output shaft constructed and arranged to shift the vehicle between a four-wheel and two-wheel drive mode; a dual drive gear operatively attached to the output shaft between the range shifter and the mode shifter constructed and arranged so that rotation of the dual drive gear drives the range shifter and the mode shifter; and at least one plunger radially displaced around the output shaft which is actuated by the dual drive gear to engage a slot between the plurality of teeth on the output shaft to prevent rotation of the shaft during a range shift.

Abstract: A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.

Abstract: A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.

Abstract: An axle disconnect assembly for translating rotational torque between an output shaft and an axle shaft of a vehicle driveline; including: disconnect housing and a clutch supported therein. The clutch is disposed in selective torque translating relationship between the output shaft and the axle shaft, and is movable between: an engaged configuration wherein torque is translated between the output shaft and the axle shaft; and a disengaged configuration wherein torque is interrupted between the shafts. An electromagnetic actuator is provide and has a slider selectively movable between a first stable position and a second stable position. The actuator is disposed in force translating relationship with the clutch such that movement from one stable position to the other stable position causes corresponding movement of the clutch between the configurations so as to selectively translate rotational torque between the output shaft and the axle shaft.

Abstract: A number of variations may include a transfer case comprising an input shaft and a first output shaft sharing a primary axis of rotation; a second output shaft offset from the first output shaft; a range shifter comprising a first cam constructed and arranged to selectively shift a vehicle to a high-range drive mode, a low range drive mode, or a neutral drive mode; a mode shifter comprising a second cam constructed and arranged to actuate a synchronizer which selectively shifts the vehicle between a two-wheel drive mode and a four-wheel drive mode a gear train having a first axis offset from the primary axis, and a reversible electric motor which drives the gear train wherein direction of the rotation of the electric motor determines engagement or disengagement of the mode shifter to selectively shift the vehicle between the two-wheel drive mode and the four-wheel drive mode.

Abstract: An axle disconnect assembly for translating rotational torque between an output shaft and an axle shaft of a vehicle driveline; including: disconnect housing and a clutch supported therein. The clutch is disposed in selective torque translating relationship between the output shaft and the axle shaft, and is movable between: an engaged configuration wherein torque is translated between the output shaft and the axle shaft; and a disengaged configuration wherein torque is interrupted between the shafts. An electromagnetic actuator is provide and has a slider selectively movable between a first stable position and a second stable position. The actuator is disposed in force translating relationship with the clutch such that movement from one stable position to the other stable position causes corresponding movement of the clutch between the configurations so as to selectively translate rotational torque between the output shaft and the axle shaft.

Abstract: A transfer case (21, 330) and a method of assembly can include an input shaft (15) and output shafts (14, 16), a mode clutch (30) for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (56, 380, 480), a planetary gear assembly (20) for providing a different drive ratio between the input shaft (15) and the output shaft (14), a range shift mechanism (50, 360, 460), and a synchronizer (40, 340) for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear (24) can be connected to the planetary gear assembly (20) during the high-range and low-range drive mode. The mode shift mechanism (56) and the range shift mechanism (50) can be electro-mechanically actuated by a reversible rotatable actuating gear (348, 448) interposed between an expandable clutch actuator (388, 488) and a rotatable barrel cam (359, 459).

Abstract: A transfer case (21, 330) and a method of assembly can include an input shaft (15) and output shafts (14, 16), a mode clutch (30) for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (56, 380, 480), a planetary gear assembly (20) for providing a different drive ratio between the input shaft (15) and the output shaft (14), a range shift mechanism (50, 360, 460), and a synchronizer (40, 340) for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear (24) can be connected to the planetary gear assembly (20) during the high-range and low-range drive mode. The mode shift mechanism (56) and the range shift mechanism (50) can be electro-mechanically actuated by a reversible rotatable actuating gear (348, 448) interposed between an expandable clutch actuator (388, 488) and a rotatable barrel cam (359, 459).