Abstract: An axle assembly that has a lubricant reservoir. The lubricant reservoir may be disposed above a differential assembly and may capture lubricant that is splashed by the differential assembly. The lubricant reservoir may have at least one tank. The lubricant reservoir may optionally provide lubricant to a lubricant distribution trough.

Abstract: An axle assembly having a fill-check assembly. A fill-check assembly is disposed on the axle housing and may include a fitting, a guard, and a sight glass in fluid communication with a lubricant reservoir via the fitting. The sight glass permits visual inspection of the lubricant in the sight glass.

Abstract: A rear cover for a drive axle housing is provided that minimizes stresses in the weld joining the output shaft bearing tube to the rear cover. In one embodiment, the rear cover includes a stiffening rib extending transversely across part or all of the cover. In another embodiment, the rear cover includes a raised portions proximate the output shaft bearing tube that is substantially spherical in shape.

Abstract: A drive axle assembly is provided with a reduced part count and improved alignment. The assembly includes a drive axle housing with input and output shafts and an inter-axle differential that is driven by the input shaft. The inter-axle differential is drivingly coupled to the output shaft and divides power between first and second axles. The output shaft is a unitary member and defines a yoke at one end disposed outside of the drive axle housing and restrained against axial movement within the drive axle housing. A bearing set is disposed between the output shaft and the drive axle housing and includes first and second bearing cones and a unitary bearing cup. The bearing cup includes threads that engage corresponding threads in the drive axle housing.

Abstract: The present invention comprises a breather system and a method of using the system. The assembly has a breather tube, a baffle system at least partially located within the breather tube and a drain back tube connected to the breather tube. The baffle system has a plurality of baffles designed to prevent lubricant from escaping a housing while still allowing air to pass into and out of the housing.

Abstract: A method for converting a non-driven tag axle system to a driven axle system is disclosed where a forward driven axle system is converted to drive an interaxle drive shaft. The interaxle drive shaft is connected to a drive axle head mounted within the tag axle housing. Drive axles are connected to drive axle head. In another embodiment, a forward driven axle system is removed from a first position on the vehicle frame and the tag axle is removed from a second position on the vehicle frame. A differential is installed in the tag axle and it is located in the first position. The forward driven axle system is located in the second position and connected to the differential in the first position.

Abstract: A gasket for a drive axle of a vehicle has an inner periphery defining an aperture and an outer periphery having a first diameter portion and a second diameter portion. The second diameter portion is greater than the first diameter portion. The gasket also has an intermediate portion between the peripheries. The intermediate portion has a plurality of apertures defined therein.

Abstract: A method for converting a non-driven tag axle system to a driven axle system is disclosed where a forward driven axle system is converted to drive an interaxle drive shaft. The interaxle drive shaft is connected to a drive axle head mounted within the tag axle housing. Drive axles are connected to drive axle head. In another embodiment, a forward driven axle system is removed from a first position on the vehicle frame and the tag axle is removed from a second position on the vehicle frame. A differential is installed in the tag axle and it is located in the first position. The forward driven axle system is located in the second position and connected to the differential in the first position.

Abstract: A method for converting a non-driven tag axle system to a driven axle system is disclosed where a forward driven axle system is converted to drive an interaxle drive shaft. The interaxle drive shaft is connected to a drive axle head mounted within the tag axle housing. Drive axles are connected to drive axle head. In another embodiment, a forward driven axle system is removed from a first position on the vehicle frame and the tag axle is removed from a second position on the vehicle frame. A differential is installed in the tag axle and it is located in the first position. The forward driven axle system is located in the second position and connected to the differential in the first position.

Abstract: An improved inter-axle differential locking clutch is provided that aligns the actuator and the clutch member thereby reducing space and material requirements in the axle assembly housing. The clutch also eliminates the need for a pushrod and shift fork thereby reducing tooling and production costs, as well as eliminating issues associated with misalignment of the piston and pushrod, relative rotation of the shift fork and clutch member, and tipping of the shift fork. The clutch includes one or more pistons disposed within either the axle housing or a carrier supporting the input shaft bearing. Fluid pressure actuates the pistons against a clutch member causing selective engagement between the clutch member and either a side gear driven by the inter-axle differential or a differential case housing the differential gears of the inter-axle differential.

Abstract: An improved lubrication system for drive axle assemblies is provided that uses a collector in connection with a filter plug to lower the dynamic lubricant level in the drive axle assembly and filter contaminants in the lubricant sump. The collector is affixed to a cover plate attached to the drive axle housing and defines a well and a flow passage proximate the bottom of the well. The flow passage is aligned with an opening through which lubricant is inserted into the housing. A plug with a filter is inserted through the opening in the cover plate and into the flow passage. The invention reduces churning losses by lowering the dynamic lubricant level in the axle assembly without having a negative impact on lubricant life.

Abstract: An improved differential carrier and pilot web for a vehicle comprises a carrier and a separate pilot web. The pilot web is attached to the carrier by at least two bolts. At least two bolts are each covered by a bushing. The carrier and the pilot web each preferably comprise counter bored holes to receive and support the bolt and bushing. The carrier and the pilot web each also have a mating stop surface, which are precision machined to be a minimal distance from one another.

Abstract: A differential assembly includes a yoke, attached to a drive shaft, for driving a pinion head. The differential assembly further includes inner and outer pinion bearing assemblies, a separable mounting plate, and a cavity defined by a housing for receiving a pinion assembly. The outer pinion bearing assembly is integrally mounted to the housing, while the inner pinion bearing assembly is secured to the separable mounting plate. The pinion head is straddle mounted between the inner and outer pinion bearing assemblies.

Abstract: The present invention comprises a breather system and a method of using the system. The assembly has a breather tube, a baffle system at least partially located within the breather tube and a drain back tube connected to the breather tube. The baffle system has a plurality of baffles designed to prevent lubricant from escaping a housing while still allowing air to pass into and out of the housing.

Abstract: A differential assembly includes a yoke, attached to a drive shaft, for driving a pinion head. The differential assembly further includes inner and outer pinion bearing assemblies, a separable mounting plate, and a cavity defined by a housing for receiving a pinion assembly. The outer pinion bearing assembly is integrally mounted to the housing, while the inner pinion bearing assembly is secured to the separable mounting plate. The pinion head is straddle mounted between the inner and outer pinion bearing assemblies.

Abstract: A differential having pinion bearings supported on the input yoke is provided. The differential includes a housing having an opening through which a pinion shaft extends. The input yoke is disposed about a portion of the pinion shaft and one or both pinion bearing sets are then disposed about the input yoke. This configuration reduces pinion standout and allows for installation of a pre-assembled bearing pack (i.e., without spacers or shims), but does not reduce the length of the splines on the input yoke or bearing capacity.

Abstract: The present invention relates to an actuation enhancement for an automated vehicle inter-axle differential (IAD) locking system. The vehicle having an engine and a tandem drive axle. The IAD actuation enhancement locking system comprises a rotating sliding clutch and a rotating side helical gear, which are capable of an engagement mode and a disengagement mode, a microprocessor, and an electrical connection between the microprocessor and an engine electronic control unit. When the sliding clutch and the helical gear are placed in the engagement mode or are placed in the disengagement mode, the microprocessor momentarily communicates a data link message to the engine electronic control unit to break engine torque, which has been found to facilitate engagement or disengagement of the sliding clutch and the helical gear.

Abstract: The present invention relates to an automatic inter-axle differential lock actuation sensing method for a vehicle having a tandem drive axle. The inter-axle differential lock actuation sensing method comprises providing a clutch locking mechanism of an inter-axle differential for a vehicle, the clutch locking mechanism having a first set of teeth in a fixed position and a second set of teeth on a sliding clutch, locating a speed sensor such that when the clutch mechanism is disengaged the sensor measures a speed of the sliding clutch, and when the clutch mechanism is fully engaged the sensor measures zero speed even though the sliding clutch continues to rotate, providing a speed of the vehicle from a vehicle data link, and using the speed sensor-speed and the vehicle speed to determine status of clutch mechanism engagement.

Abstract: The present invention relates to an automatic inter-axle differential (IAD) locking system for a vehicle having a tandem drive axle. The IAD lock system comprises a vehicle IAD having a rotating sliding clutch mechanism and a rotating side helical gear. If the absolute difference between the sliding clutch revolutions per minute (RPM) and the side helical gear RPM is greater than a minimum limit, and if the absolute difference between the sliding clutch RPM and the side helical gear RPM is less than a maximum limit, and the speed of the vehicle is less than a third limit, then a microprocessor engages the IAD lock mechanism.

Abstract: A method for converting a non-driven tag axle system to a driven axle system is disclosed where a forward driven axle system is converted to drive an interaxle drive shaft. The interaxle drive shaft is connected to a drive axle head mounted within the tag axle housing. Drive axles are connected to drive axle head. In another embodiment, a forward driven axle system is removed from a first position on the vehicle frame and the tag axle is removed from a second position on the vehicle frame. A differential is installed in the tag axle and it is located in the first position. The forward driven axle system is located in the second position and connected to the differential in the first position.