Abstract: A planetary transmission having a planet carrier with a carrier body and a plurality of carrier pins. The carrier body includes a pair of carrier plates, each of which having pin bosses that extend outwardly from a remaining portion of the carrier plate. The pin bosses on at least one of the carrier plates define an exterior surface with at least one step so that portions of the exterior surface of the pin bosses are spaced apart in an axial direction. The carrier pins have an axial ends with recesses formed therein such that each axial end of each carrier pin terminates in a thin wall section. The carrier pins are received through the carrier plates and the thin wall sections are deformed against the exterior surfaces of the pin bosses to retain the carrier pins to the carrier body.

Abstract: An AWD system can include a differential, a PTU, and a friction clutch. A differential input can receive torque from the powertrain and rotate about a first axis. First and second differential outputs can rotate about the first axis. A third output can be drivingly coupled to the differential input and rotatable about a second axis transverse to the first axis. The clutch can include first friction members, second friction members, and an actuator. The first friction members can be coupled to the differential input for common rotation. The second friction members can be coupled to the second differential output for common rotation. The actuator can selectively engage the first friction members with the second friction members. The secondary driveline can include a second input member coupled to the third output to receive rotary power therefrom. The second driveline can distribute rotary power for driving the second set of wheels.

Abstract: A drive module having a housing, an input pinion, a ring gear driven by the input pinion, a ring gear bearing supporting the ring gear for rotation relative to the housing, a pair of output shafts and a clutch that selectively transmits rotary power between the ring gear and the output shafts. The clutch includes a clutch input, which is rotatably coupled to the ring gear, a clutch plate separator that is rotatably coupled to the clutch input, a pair of clutch outputs, which are each coupled to a respective one of the output shafts, a pair of clutch packs, which transmit rotary power between the clutch input and a respective one of the clutch outputs, and a pair of apply pistons. The apply pistons are housed in the clutch plate separator.

Abstract: A vehicle driveline component having a limited slip differential with a differential gearset and a pair of clutch packs received in a differential case. The differential gearset employs side gears that are meshed with first differential pinions, which are mounted about a first pin axis, and second differential pinions, which are mounted about a second pin axis that is not perpendicular to the first pin axis. The teeth of the first differential pinions are formed with drive side having a first pressure angle. The teeth of the second differential pinions are formed with a coast side having a second pressure angle that is different from the first pressure angle. The teeth of the side gears are asymmetric and have a first side, which is formed with the first pressure angle, and a second side that is formed with the second pressure angle.

Abstract: A vehicle driveline component having a limited slip differential with a differential gearset and a pair of clutch packs received in a differential case. The differential gearset employs side gears that are meshed with first differential pinions, which are mounted about a first pin axis, and second differential pinions, which are mounted about a second pin axis that is not perpendicular to the first pin axis. The teeth of the first differential pinions are formed with drive side having a first pressure angle. The teeth of the second differential pinions are formed with a coast side having a second pressure angle that is different from the first pressure angle. The teeth of the side gears are asymmetric and have a first side, which is formed with the first pressure angle, and a second side that is formed with the second pressure angle.

Abstract: A power transmitting component can include a planetary differential including a differential case. The planet carrier can be disposed within the differential case and rotatable about the output axis relative thereto. The first output member can be coupled to the planet carrier for common rotation about the output axis. The second output member can be coupled to the sun gear for common rotation about the output axis. A clutch basket can be fixedly coupled to the planet carrier and disposed within the differential case. A set of first friction plates can be coupled to the clutch basket for common rotation about the output axis therewith and for axial translation relative to the clutch basket. A set of second friction plates can be coupled to the sun gear for common rotation about the output axis and for axial translation relative to the sun gear.

Abstract: An axle assembly having an axle housing, an axle shaft, a plurality of axle shaft bearings and a seal. The axle housing has a tubular member and an end flange that is coupled to the tubular member. The axle shaft bearings and the seal are received in the end flange and are engaged to the axle shaft. The axle shaft bearings support the axle shaft for rotation relative to the axle housing. The seal is sealingly engaged to the end flange and the axle shaft. A method for assembling an axle assembly is also provided.

Abstract: An axle assembly that includes a housing assembly, an input pinion, a ring gear, a ring gear bearing, and a differential assembly having a differential case. The ring gear bearing supports the ring gear for rotation on the housing assembly as well as handles thrust loads between the ring gear and the housing assembly in opposite axial directions. The ring gear bearing includes an outer bearing race having a first race member, which may be unitarily and integrally formed with the ring gear, and a second race member that is received in a groove formed on the ring gear. The differential case is coupled to the ring gear and secures the second race member to the ring gear.

Abstract: An actuator assembly can include a housing, first and second pistons, and spring. The housing can include first and second cylinders disposed about an axis. The first piston and cylinder can define a first chamber in fluid communication with an inlet. The second piston and cylinder can define a second chamber in fluid communication with an outlet. Opposite ends of the spring can be coupled for axial translation with the first and second piston, respectively. The spring can translate the first piston to provide high volume, low pressure fluid to the outlet when a pressure in the first chamber is less than a predetermined pressure. When the pressure in the first chamber is equal to, or greater than, the predetermined pressure and the second piston is translated in the first axial direction, the spring can compress and the second piston can provide low volume, high pressure fluid to the outlet.

Abstract: A disconnecting axle includes a housing assembly including a first end cap coupled to a first side of a housing member to define a clutch cavity, and a second end cap coupled to a second side of the housing member to define a differential cavity. The housing member can define a central bore, a sump, and a plurality of passages. The central bore extends axially between the clutch and differential cavities. The sump can be spaced apart from the clutch and differential cavities, and the central bore. A clutch passage couples the clutch cavity to the sump. A differential passage couples the differential cavity to the sump. A first output member of the differential extends axially within the central bore. A piston is configured to compress friction plates to selectively transmit torque. A pump can pump fluid from the sump to the cylinder to move the piston.

Abstract: A clutched device can include a differential, a clutch, and a gate. The differential can transmit torque between an input member and first and second output members. A housing can define a sump and a reservoir spaced apart from the sump. A first aperture open to the sump and reservoir can be above a static fluid level of the sump. A second aperture can couple the sump and reservoir below the static fluid level. An outer clutch plate carrier can rotate through the sump and sling fluid through the first aperture. The outer carrier can be coupled for rotation with the second output member and an inner clutch plate carrier can be coupled to a third output member. The gate can be movable between first and second positions. In the first position the gate can block the second aperture. In the second position the second aperture can be open.

Abstract: A clutched device has a housing, which defines a clutch sump, a friction clutch that is received in the housing, a first reservoir, an evacuation device and a pump that is configured to transmit fluid between the first reservoir and the friction clutch for operating the friction clutch. The evacuation device is selectively operable for changing the effective volume of the clutch sump so that the level of lubrication in the clutch sump can be lowered to reduce drag forces caused by the presence of lubricant between clutch plates of the friction clutch when the friction clutch is not in use.

Abstract: An all-wheel drive vehicle drivetrain can include an input member, first and second output members, a planetary differential, a first clutch, and a second clutch. The differential can include an internal gear, a carrier, a sun gear, and a differential gear set. The internal gear can be coupled to the input member to receive input torque about an axis. The carrier can be coupled to the first output for common rotation about the axis. The differential gear set can receive input torque from the internal gear and output differential torque to the carrier and the sun gear. The first clutch can be operable to selectively couple and decouple the sun gear with the second output member for common rotation. The second clutch can be operable to selectively transmit torque between the carrier and the second output member.

Abstract: A family of axle assemblies that employ a modular concept to maximize part commonality amongst the several axle assemblies. The axle assemblies have a housing assembly that employs a main housing that is formed from a casting that is common to all of the axle assemblies.

Abstract: A disconnecting axle assembly for a vehicle can include a planetary differential and a clutch. The differential input can be meshingly engaged with an input pinion. The clutch can include first and second friction plates. The first plates can be non-rotatably but axially slidably coupled to a first differential output. The second plates can be interleaved with the first plates and non-rotatably but axially slidably coupled to a first axle half-shaft which can drive a first wheel. A second differential output can be drivingly coupled to a second axle half-shaft which can drive a second wheel. The differential can output a greater amount of torque to the first differential output than the second differential output when the vehicle is traveling in a straight line.

Abstract: A power transmitting component can include a planetary differential including a differential case. The planet carrier can be disposed within the differential case and rotatable about the output axis relative thereto. The first output member can be coupled to the planet carrier for common rotation about the output axis. The second output member can be coupled to the sun gear for common rotation about the output axis. A clutch basket can be fixedly coupled to the planet carrier and disposed within the differential case. A set of first friction plates can be coupled to the clutch basket for common rotation about the output axis therewith and for axial translation relative to the clutch basket. A set of second friction plates can be coupled to the sun gear for common rotation about the output axis and for axial translation relative to the sun gear.

Abstract: An axle assembly that includes a housing assembly, an input pinion, a ring gear, a ring gear bearing, and a differential assembly having a differential case. The ring gear bearing supports the ring gear for rotation on the housing assembly as well as handles thrust loads between the ring gear and the housing assembly in opposite axial directions. The ring gear bearing includes an outer bearing race having a first race member, which may be unitarily and integrally formed with the ring gear, and a second race member that is received in a groove formed on the ring gear. The differential case is coupled to the ring gear and secures the second race member to the ring gear.

Abstract: A disconnecting axle includes a housing assembly including a first end cap coupled to a first side of a housing member to define a clutch cavity, and a second end cap coupled to a second side of the housing member to define a differential cavity. The housing member can define a central bore, a sump, and a plurality of passages. The central bore extends axially between the clutch and differential cavities. The sump can be spaced apart from the clutch and differential cavities, and the central bore. A clutch passage couples the clutch cavity to the sump. A differential passage couples the differential cavity to the sump. A first output member of the differential extends axially within the central bore. A piston is configured to compress friction plates to selectively transmit torque. A pump can pump fluid from the sump to the cylinder to move the piston.

Abstract: An axle assembly with a housing, a shaft received in the housing, a shaft bearing supporting the shaft for rotation relative to the housing about a shaft axis, a differential assembly, an annular band and a secondary retainer. The shaft bearing has an inner race, which is received on and directly engaged to the shaft, and an outer race that is received on and directly engaged to the axle housing. The differential assembly has an output member that is non-rotatably coupled to the shaft. The annular band is fixedly coupled to the shaft at a location along the axle shaft axis between the inner race and the output member. The secondary retainer is disposed along the axle shaft axis between the annular band and the output member and is configured to limit movement of the annular band along the axle shaft axis in a direction toward the output member.

Abstract: An AWD system can include a differential, a PTU, and a friction clutch. A differential input can receive torque from the powertrain and rotate about a first axis. First and second differential outputs can rotate about the first axis. A third output can be drivingly coupled to the differential input and rotatable about a second axis transverse to the first axis. The clutch can include first friction members, second friction members, and an actuator. The first friction members can be coupled to the differential input for common rotation. The second friction members can be coupled to the second differential output for common rotation. The actuator can selectively engage the first friction members with the second friction members. The secondary driveline can include a second input member coupled to the third output to receive rotary power therefrom. The second driveline can distribute rotary power for driving the second set of wheels.