Abstract: An automotive driveline disconnect assembly includes a first clutch part and a second clutch part, and is designed and constructed to preclude an occupant-audible noise from being made between components of the disconnect assembly. The preclusion of the occupant-audible noise can be effected via one or more dampers, a non-flat tooth profile, or a combination of these measures. The disconnect assembly can be equipped in a larger automotive driveline component such as a power transfer unit (PTU), a final drive unit (FDU), a rear drive module (RDM), or an electronic differential locker (EDL).

Abstract: In at least some implementations, a clip for restricting the axial movement of at least one of an inner shaft or an outer shaft relative to the other shaft includes a first free end, a second free end, an opening defining an open end of the clip between the first free end and the second free end, a closed end opposite the open end, at least three control zones, and a plurality of intermediate zones. Each intermediate zone has a varying width and each is disposed adjacent to at least one of the at least three control zones.

Abstract: In at least some implementations, a disconnect assembly for a driveline component, such as a power transfer unit, may include an input shaft, a disconnect shaft selectively rotated by the input shaft and an output shaft coupled to the disconnect shaft. A first gear is coupled to the disconnect shaft and a second gear is coupled to the output shaft and to the first gear so that the output shaft rotates when the disconnect shaft rotates. A connection feature is movable between an engaged position in which the input shaft and disconnect shaft are coupled and a disengaged position in which the input shaft rotates relative to the disconnect shaft. The connection feature includes a first part carried by the gear for rotation therewith and a second part movable relative to the first part and carried by the input shaft for rotation with the input shaft.

Abstract: An automotive driveline disconnect assembly includes a first clutch part and a second clutch part, and is designed and constructed to preclude an occupant-audible noise from being made between components of the disconnect assembly. The preclusion of the occupant-audible noise can be effected via one or more dampers, a non-flat tooth profile, or a combination of these measures. The disconnect assembly can be equipped in a larger automotive driveline component such as a power transfer unit (PTU), a final drive unit (FDU), a rear drive module (RDM), or an electronic differential locker (EDL).

Abstract: In at least some implementations, a constant velocity joint includes a first rotational member and a boot can assembly coupled to the first rotational member. The boot can assembly includes a boot can, a boot and a seal carried by the boot can and arranged to engage and seal against the first rotational member when the boot can assembly is coupled to the first rotational member. The boot and seal may be formed from the same piece of material and may be bonded to the boot can. The boot and seal may be overmolded onto the boot can.

Abstract: A vehicle power transfer unit (PTU) disconnect assembly can include a first shaft, a second shaft, and a collar assembly. The first shaft has a first split-spline at its exterior surface. The second shaft is telescoped over the first shaft and has a set of splines at its exterior surface. A helical gear is carried by the second shaft. The collar assembly is situated around both of the first and second shafts. The collar assembly has a second split-spline at its interior surface.

Abstract: In at least some implementations, a clip for restricting the axial movement of at least one of an inner shaft or an outer shaft relative to the other shaft includes a first free end, a second free end, an opening defining an open end of the clip between the first free end and the second free end, a closed end opposite the open end, at least three control zones, and a plurality of intermediate zones. Each intermediate zone has a varying width and each is disposed adjacent to at least one of the at least three control zones.

Abstract: In at least some implementations, a disconnect assembly for a driveline component, such as a power transfer unit, may include an input shaft, a disconnect shaft selectively rotated by the input shaft and an output shaft coupled to the disconnect shaft. A first gear is coupled to the disconnect shaft and a second gear is coupled to the output shaft and to the first gear so that the output shaft rotates when the disconnect shaft rotates. A connection feature is movable between an engaged position in which the input shaft and disconnect shaft are coupled and a disengaged position in which the input shaft rotates relative to the disconnect shaft. The connection feature includes a first part carried by the gear for rotation therewith and a second part movable relative to the first part and carried by the input shaft for rotation with the input shaft.

Abstract: In at least some implementations, a disconnect assembly for a driveline component, such as a power transfer unit, may include an input shaft, a disconnect shaft selectively rotated by the input shaft and an output shaft coupled to the disconnect shaft. A first gear is coupled to the disconnect shaft and a second gear is coupled to the output shaft and to the first gear so that the output shaft rotates when the disconnect shaft rotates. A connection feature is movable between an engaged position in which the input shaft and disconnect shaft are coupled and a disengaged position in which the input shaft rotates relative to the disconnect shaft. The connection feature includes a first part carried by the gear for rotation therewith and a second part movable relative to the first part and carried by the input shaft for rotation with the input shaft.

Abstract: In at least some implementations, a constant velocity joint includes a first rotational member and a boot can assembly coupled to the first rotational member. The boot can assembly includes a boot can, a boot and a seal carried by the boot can and arranged to engage and seal against the first rotational member when the boot can assembly is coupled to the first rotational member. The boot and seal may be formed from the same piece of material and may be bonded to the boot can. The boot and seal may be overmoulded onto the boot can.

Abstract: A vehicle power transfer unit (PTU) disconnect assembly can include a first shaft, a second shaft, and a collar assembly. The first shaft has a first split-spline at its exterior surface. The second shaft is telescoped over the first shaft and has a set of splines at its exterior surface. A helical gear is carried by the second shaft. The collar assembly is situated around both of the first and second shafts. The collar assembly has a second split-spline at its interior surface.

Abstract: In at least some implementations, a disconnect assembly for a driveline component, such as a power transfer unit, may include an input shaft, a disconnect shaft selectively rotated by the input shaft and an output shaft coupled to the disconnect shaft. A first gear is coupled to the disconnect shaft and a second gear is coupled to the output shaft and to the first gear so that the output shaft rotates when the disconnect shaft rotates. A connection feature is movable between an engaged position in which the input shaft and disconnect shaft are coupled and a disengaged position in which the input shaft rotates relative to the disconnect shaft. The connection feature includes a first part carried by the gear for rotation therewith and a second part movable relative to the first part and carried by the input shaft for rotation with the input shaft.

Abstract: An exemplary constant velocity joint includes a first member and a second member rotatably engaging the first member. A clutch pack is disposed between and engages the first and second members. A fastener is used to attach the first member to the second member. The fastener is fixedly connected to the second member and rotatably engages the first member. The fastener exerts a biasing force for urging the first and second members into engagement with the clutch pack.

Abstract: An automotive shaft assembly is provided including a first barshaft having a first connection end and a second barshaft having a second connection end. A connection tube rotationally engages the first connection to the second connection end and includes a shear diameter configured to experience shear failure in the presence of an overload torque such that the first connection end is rotationally disengaged the said second connection end.

Abstract: A vehicle joint assembly is provided comprising an outer race having an outer surface and an inner surface. A pair of opposed slot tracks are formed in the inner cup surface and each comprise a track top wall and two track sidewalls. A barshaft is in communication with a bipod element comprised of a body portion and two opposed peg portions. Each of the two opposed peg portions comprises two opposed curved engagement surfaces engaging one of the track sidewalls. The bipod element is positioned within the outer race such that each of the opposed peg portions resides in one of the opposed slot tracks. The bipod element is capable of being positioned in a variety of angles within the slot tracks and is capable of plunging within the slot tracks.

Abstract: A vehicle joint assembly is provided comprising an outer race having an outer surface and an inner surface. A pair of opposed slot tracks are formed in the inner cup surface and each comprise a track top wall and two track sidewalls. A barshaft is in communication with a bipod element comprised of a body portion and two opposed peg portions. Each of the two opposed peg portions comprises two opposed curved engagement surfaces engaging one of the track sidewalls. The bipod element is positioned within the outer race such that each of the opposed peg portions resides in one of the opposed slot tracks. The bipod element is capable of being positioned in a variety of angles within the slot tracks and is capable of plunging within the slot tracks.

Abstract: An automotive shaft assembly is provided including a first barshaft having a first connection end and a second barshaft having a second connection end. A connection tube rotationally engages the first connection to the second connection end and includes a shear diameter configured to experience shear failure in the presence of an overload torque such that the first connection end is rotationally disengaged the said second connection end.

Abstract: An exemplary constant velocity joint includes a first member and a second member rotatably engaging the first member. A clutch pack is disposed between and engages the first and second members. A fastener is used to attach the first member to the second member. The fastener is fixedly connected to the second member and rotatably engages the first member. The fastener exerts a biasing force for urging the first and second members into engagement with the clutch pack.