Abstract: A differential with a washer for a gear in a differential housing includes an outer edge at a maximum radial distance from an axis, and an inner edge defining an opening, the inner edge defined in part by an innermost portion at a minimum radial distance from the axis and the inner edge having an outward portion spaced radially outwardly from the innermost portion. The washer also includes an axially and radially inclined sidewall extending at least part of the way between the outer edge and the innermost portion.

Abstract: In at least one implementation, a method of assembling gears into a housing of an automotive differential includes, selecting a thickness dimension of first and second pinion gear washers, and first and second side gear washers, locating a pair of pinion gears, a pinion shaft and a pair of side gears at least partially within an interior of the housing with the pinion gear washers between the housing and separate ones of the pinion gears, and the side gear washers between the housing and separate ones of the side gears. The thickness of the side gear washers may be a function of target side gear apex positions and relative to a pinion gear apex axis. The thickness of the pinion gear washers may be a function of target pinion gear apex positions residing along a pinion gear apex axis and relative to a side gear apex axis.

Abstract: A differential with a washer for a gear in a differential housing includes an outer edge at a maximum radial distance from an axis, and an inner edge defining an opening, the inner edge defined in part by an innermost portion at a minimum radial distance from the axis and the inner edge having an outward portion spaced radially outwardly from the innermost portion. The washer also includes an axially and radially inclined sidewall extending at least part of the way between the outer edge and the innermost portion.

Abstract: In at least one implementation, a method of assembling gears into a housing of an automotive differential includes, selecting a thickness dimension of first and second pinion gear washers, and first and second side gear washers, locating a pair of pinion gears, a pinion shaft and a pair of side gears at least partially within an interior of the housing with the pinion gear washers between the housing and separate ones of the pinion gears, and the side gear washers between the housing and separate ones of the side gears. The thickness of the side gear washers may be a function of target side gear apex positions and relative to a pinion gear apex axis. The thickness of the pinion gear washers may be a function of target pinion gear apex positions residing along a pinion gear apex axis and relative to a side gear apex axis.

Abstract: A housing of a vehicle differential, such as an automotive driveline differential, supports one or more gearsets in assembly. A wall of the housing has one or more windows that provide access to the gearset(s). One or more protuberances are situated at an exterior surface of the wall and near the window(s). The protuberance(s) provide a thickened portion in the wall to strengthen and reinforce the wall against stresses experienced during use of the vehicle differential.

Abstract: A differential flange assembly is disclosed herein that includes a flange member and a washer member. The flange member is defined by an engagement face and having an aperture therethrough. At least one slot is formed on the engagement face so as to extend radially outward from the aperture. The washer member has at least one tab extending from a peripheral edge of the washer member and at least one opening. The tab is configured to be seated within the slot to mate the washer member to the engagement face of the flange member. The interaction of the slot of the flange member and the tab of the washer member prevent rotation of the washer member with respect to the flange member.

Abstract: A vent system for use in a driveline component of an automotive vehicle. The driveline component includes a housing and a cartridge within the housing. The driveline component includes the vent system which has a vent that is secured to the housing at an orifice within a top portion of the housing. The vent system also includes a baffle extending from the housing wherein the baffle is adjacent to the vent orifice. The vent and baffle system also includes a gap that is defined by the baffle, the housing and the cartridge and is of sufficient size to prevent pooling and the forming of a meniscus near the vent assembly. The vent and baffle system is used to allow for venting of high pressures developed during high speed rotation of driveline modules within a drive train system of an automotive vehicle without allowing the expulsion of the lubricating fluid from the oil housing.

Abstract: A vent system for use in a driveline component of an automotive vehicle. The driveline component includes a housing and a cartridge within the housing. The driveline component includes the vent system which has a vent that is secured to the housing at an orifice within a top portion of the housing. The vent system also includes a baffle extending from the housing wherein the baffle is adjacent to the vent orifice. The vent and baffle system also includes a gap that is defined by the baffle, the housing and the cartridge and is of sufficient size to prevent pooling and the forming of a meniscus near the vent assembly. The vent and baffle system is used to allow for venting of high pressures developed during high speed rotation of driveline modules within a drive train system of an automotive vehicle without allowing the expulsion of the lubricating fluid from the oil housing.