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: 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: An input bearing adjuster system includes a differential carrier assembly having a set of threads on an interior surface and an input bearing adjuster having a complementary set of threads on an exterior surface. The system also includes an input bearing system of a differential which includes an outer race in contact with the input bearing adjuster and an inner race in contact with an input shaft and an input bearing. Additionally, a locking mechanism is used to selectively secure the input bearing adjuster to the differential carrier. The threads of the bearing adjuster are engaged with the threads of the differential carrier to adjust both the preload and/or the endplay of the input bearing.

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. This is abstract submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A pinion shaft subassembly for a tandem drive axle assembly is provided. The preassembled subassembly includes a bearing cage, bearings disposed within the bearing cage, a pinion shaft disposed about an axis and supported on the bearings, and a driven gear disposed about the pinion shaft. The bearing cage defines a mounting flange that extends radially outwardly and is configured to mount to a corresponding mounting flange of a drive axle housing. The flange is configured such that the subassembly is installed in the drive axle housing from the rear of the housing rather than the forward end. As a result, the housing may be made of a unitary construction.

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: 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: 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: 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: A tandem axle assembly is provided. The tandem axle assembly includes a forward axle assembly and a rear axle assembly and an intermediate drive shaft assembly extending between the two axle assemblies. The forward and rear axle assemblies both include a pinion gear rotating responsive to an inter-axle differential and a ring gear in mesh with the pinion gear. The forward pinion gear is offset from the forward ring gear by a first predetermine distance while the rear pinion gear is offset from the rear ring ear by a second predetermined distance. The second predetermined distance is greater than zero, but is less than the first predetermined distance. The variation in offsets enables both equal working angles in the intermediate drive shaft assembly and a reduction in those angles as compared to conventional tandem axle assemblies. Further, the variation in offset results in stronger and quieter gearing.

Abstract: A tandem axle assembly is provided. The tandem axle assembly includes a forward axle assembly and a rear axle assembly and an intermediate drive shaft assembly extending between the two axle assemblies. The forward and rear axle assemblies both includes a pinion gear rotating responsive to an inter-axle differential and a ring gear in mesh with the pinion gear. The forward pinion gear is offset from the forward ring gear by a first predetermined distance while the rear pinion gear is offset from the rear ring gear by a second predetermined distance. The second predetermined distance is greater than zero, but is less than the first predetermined distance. The variation in offsets enables both equal working angles in the intermediate drive shaft assembly and a reduction in those angles as compared to conventional tandem axle assemblies. Further, the variation in offset results in stronger and quieter gearing.