Abstract: A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall, The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case.

Abstract: A differential case assembly includes a differential case having an open end and a side wall with an interior surface. A plurality of major internal splines is formed on the interior surface of the side wall, The differential case assembly further includes a gear assembly with a retainer insert and a cross pin. The retainer insert is disposed adjacent the interior surface of the side wall between a pair of the major internal splines. The retainer insert has a hole formed therein. The cross pin has an end received in the hole of the retainer insert. The gear assembly is thereby aligned within the differential case.

Abstract: An apparatus includes a mandrel having a first end and a second end, the mandrel including a cavity formed therein, a pilot disposed in the cavity formed in the mandrel, a portion of the pilot extending outwardly from the first end of the mandrel, and an insert disposed in a channel formed in the mandrel and through an exterior surface of the mandrel, wherein a portion of the pilot abuts the insert and radial outward movement of the insert is caused by an axial movement of the pilot.

Abstract: An internally splined component for transmitting torque wherein the splines are cold formed to predetermined tolerances.

Abstract: A method and tool for producing a flow formed part are disclosed, wherein the tool has an annular array of spline forming recesses for producing a flow formed part having splines and machining and production costs are minimized and efficiency is maximized.

Abstract: An improvement in manufacturing and resulting structure of a torque transmitting assembly for use in a vehicle transmission which transmits torque from a first rotating member to a second rotating member wherein production efficiency is maximized and production costs are minimized.

Abstract: A method of producing a torque transmission between a driving member and a driven member including the steps of capturing an annular gear within the interior of a hollow cylindrical shell formed of a formable material which is caused to be flow formed around a portion of the exterior of the gear to militate against any relative longitudinal and axial movement between the shell and the gear.

Abstract: A method of producing a torque transmission between a driving member and a driven member including the steps of capturing an annular gear within the interior of a hollow cylindrical shell formed of a formable material which is caused to be flow formed around a portion of the exterior of the gear to militate against any relative longitudinal and axial movement between the shell and the gear.

Abstract: The method of producing a pinion carrier comprised of two cold form cooperating carrier components, each consisting of an aperture relatively flat plate having legs extending transversely from the plate; assembling the components so that the legs of one of the components abutted the legs of the other component, and welding the abutting legs together.

Abstract: Sub-blanks having different thicknesses and/or different materials are joined together along a joint line or boundary line. The joint line can have an axial directional component and/or a radial directional component. The blank is formed into a U-shaped structure with two substantially parallel arms and the arms can be overbent toward each other by a distance that varies along the axial length of the U-shaped member. The U-shaped member can be subjected to a press forming operation to form a substantially tubular member. The substantially tubular member can have a non-circular cross-sectional shape. A step can be formed at the joint line as a result of different thickness sub-blanks. The step is placed in a press forming die facing outwardly so that the step is reduced during the press forming operation.

Abstract: An internally splined component for transmitting torque and the method of producing the same wherein the splines are cold formed to predetermined tolerances.

Abstract: A method of producing a torque transmission between a driving member and a driven member including the steps of capturing an annular gear within the interior of a hollow cylindrical shell formed of a formable material which is caused to be flow formed around a portion of the exterior of the gear to militate against any relative longitudinal and axial movement between the shell and the gear.

Abstract: The method of producing a pinion carrier comprised of two cold form cooperating carrier components, each consisting of an aperture relatively flat plate having legs extending transversely from the plate; assembling the components so that the legs of one of the components abutted the legs of the other component, and welding the abutting legs together.