Abstract: A front axle assembly with an axle housing that has first and second housing halves that each include a main housing portion, a tubular portion and a steering yoke. The main housing portion defines a cavity that houses at least a portion of a speed differentiation mechanism. The tubular portions are fixedly coupled to an associated one of the main housing portions and extend between the main housing portion and an associated one of the steering yokes. Each steering yoke is fixedly coupled to an associated tubular portion. An annular joint structure is formed where the first and second first housing halves are coupled to one another. The annular joint structure is formed about the rotary axis such that one of the first and second housing halves is inserted into the other one of the first and second housing halves along an insertion axis that is coincident with the rotary axis.

Abstract: A front axle assembly with an axle housing that has first and second housing halves that each include a main housing portion, a tubular portion and a steering yoke. The main housing portion defines a cavity that houses at least a portion of a speed differentiation mechanism. The tubular portions are fixedly coupled to an associated one of the main housing portions and extend between the main housing portion and an associated one of the steering yokes. Each steering yoke is fixedly coupled to an associated tubular portion. An annular joint structure is formed where the first and second first housing halves are coupled to one another. The annular joint structure is formed about the rotary axis such that one of the first and second housing halves is inserted into the other one of the first and second housing halves along an insertion axis that is coincident with the rotary axis.

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.

Abstract: A driving axle assembly includes an anti-lock braking system sensor, a carrier having an opening, a differential assembly including a housing rotatably mounted to the carrier and a cover pan mounted to the carrier to enclose the opening. The cover pan includes a boss having a generally planar mounting surface with an aperture therethrough. The anti-lock braking system sensor is disposed within the aperture and coupled to the cover pan.

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.

Abstract: An axle assembly having a carrier housing, an axle housing and a differential assembly and a cover assembly. The carrier housing has an access aperture for receiving the differential assembly. The axle housing is fixedly coupled to the carrier housing and is in fluid connection therewith. The cover assembly closes the access aperture and includes a venting device for venting the carrier housing and the axle housing.

Abstract: A drive axle assembly for a motor vehicle includes an axle housing a differential bearing, a differential assembly, an adjustment nut and an adjuster lock. The differential assembly is rotatably supported within the axle housing by the differential bearing. The differential bearing is coupled to the axle housing via a bearing cap having an aperture formed therein The adjustment nut has at least one retention aperture and the adjustment nut is engaged with the differential bearing such that rotation of the adjustment nut axially displaces the differential bearing. The adjuster lock includes a first portion and a second portion. The first portion has a barb disposed in the bearing cap aperture. The second portion has a first lock pin disposed in the retention aperture thereby restricting the adjustment nut from rotating relative to the bearing cap.

Abstract: A drive axle assembly for a motor vehicle includes an axle housing, a differential bearing, a differential assembly, an adjustment nut and an adjuster lock. The differential assembly is rotatably supported within the axle housing by the differential bearing. The differential bearing is coupled to the axle housing via a bearing cap having an aperture formed therein. The adjustment nut has at least one retention aperture and the adjustment nut is engaged with the differential bearing such that rotation of the adjustment nut axially displaces the differential bearing. The adjuster lock includes a first portion and a second portion. The first portion has a barb disposed in the bearing cap aperture. The second portion has a first lock pin disposed in the retention aperture thereby restricting the adjustment nut from rotating relative to the bearing cap.

Abstract: A drive axle assembly for a motor vehicle includes an axle housing, a differential bearing, a differential assembly, an adjustment nut and an adjuster lock. The differential assembly is rotatably supported within the axle housing by the differential bearing. The differential bearing is coupled to the axle housing via a bearing cap having an aperture formed therein The adjustment nut has at least one retention aperture and the adjustment nut is engaged with the differential bearing such that rotation of the adjustment nut axially displaces the differential bearing. The adjuster lock includes a first portion and a second portion. The first portion has a barb disposed in the bearing cap aperture. The second portion has a first lock pin disposed in the retention aperture thereby restricting the adjustment nut from rotating relative to the bearing cap.

Abstract: A final drive unit for a motor vehicle has a differential gear set rotationally mounted in a gear housing that has a rearward facing cover. The differential gear set includes a differential case driven by a ring gear. The ring gear dips into lubricant in the bottom of the gear housing and pumps a portion of the lubricant through a lubricant cooling passage in the cover having a plurality of vertical parallel open ended conduits connected to a manifold having an inlet at the bottom of the cover.