Abstract: A vehicle transaxle includes a housing, an electric machine, and rotating components. The housing defines an internal cavity, a first channel, and a second channel. The first and second channels branch from a common inlet. The electric machine and rotating components are disposed within the internal cavity. The first channel is configured to deliver fluid to the electric machine for cooling. The second channel is configured to deliver the fluid to the rotating components for lubrication. The cooling channel is sized relative to the lubrication channel such that the fluid is biased from the inlet and toward the second channel in response to a temperature of the fluid being less than a threshold and is biased from the inlet and toward the first channel in response to the temperature of the fluid being greater than the threshold.

Abstract: A motor for an electric vehicle includes a motor housing for receiving a stator. A plurality of caps each have an outer rim and a washer portion defining a bolt receiving opening. The outer rim of each of the caps is press-fit into the receptacles in the motor housing. The caps are each attached to the stator by one of the bolts. The heads of the bolts clamp the cap to the stator to retain one end of the stator. The outer rim holds the cap in the motor housing while the washer portion flexes axially in response to thermal expansion and contraction of the motor housing. A method is disclosed for assembling the stator into the motor housing.

Abstract: An electric powertrain includes an electric machine having a rotor shaft supported for rotation about an axis. A planetary gearset is supported about the axis and includes a sun gear assembly having a sun shaft with a first end connected to the rotor shaft, a second end having a sun gear, and an inner bearing seat disposed therebetween. The planetary gearset further includes a planet carrier having planet gears and defining an outer bearing seat. At least one of the planet gears meshes with the sun gear. The planetary gearset also includes a ring gear meshing with at least one of the planet gears. A sun bearing is supported about the axis and includes an outer race disposed on the outer bearing seat, an inner race disposed on the inner bearing seat, and a plurality of spherical roller elements disposed between the inner and outer races.

Abstract: A motor for an electric vehicle includes a motor housing for receiving a stator. A plurality of caps each have an outer rim and a washer portion defining a bolt receiving opening. The outer rim of each of the caps is press-fit into the receptacles in the motor housing. The caps are each attached to the stator by one of the bolts. The heads of the bolts clamp the cap to the stator to retain one end of the stator. The outer rim holds the cap in the motor housing while the washer portion flexes axially in response to thermal expansion and contraction of the motor housing. A method is disclosed for assembling the stator into the motor housing.

Abstract: An electric powertrain includes an electric machine having a rotor shaft supported for rotation about an axis. A planetary gearset is supported about the axis and includes a sun gear assembly having a sun shaft with a first end connected to the rotor shaft, a second end having a sun gear, and an inner bearing seat disposed therebetween. The planetary gearset further includes a planet carrier having planet gears and defining an outer bearing seat. At least one of the planet gears meshes with the sun gear. The planetary gearset also includes a ring gear meshing with at least one of the planet gears. A sun bearing is supported about the axis and includes an outer race disposed on the outer bearing seat, an inner race disposed on the inner bearing seat, and a plurality of spherical roller elements disposed between the inner and outer races.

Abstract: A vehicle transaxle includes a housing, an electric machine stator, a plurality of mounting plates, and a first set of fasteners. The housing has internal walls that define a cavity and an access opening to the cavity. The electric machine stator is disposed within the cavity between a first of the internal walls and the opening. The plurality of mounting plates secures a first longitudinal end of the stator to the housing proximate the opening. Each fastener of the first set of fasteners extends through one of the mounting plates, through the stator, and engages the first of the internal walls to secure a second longitudinal end of the stator to the first of the internal walls.

Abstract: A vehicle transaxle includes a housing, an electric machine stator, a plurality of mounting plates, and a first set of fasteners. The housing has internal walls that define a cavity and an access opening to the cavity. The electric machine stator is disposed within the cavity between a first of the internal walls and the opening. The plurality of mounting plates secures a first longitudinal end of the stator to the housing proximate the opening. Each fastener of the first set of fasteners extends through one of the mounting plates, through the stator, and engages the first of the internal walls to secure a second longitudinal end of the stator to the first of the internal walls.

Abstract: A vehicle transmission includes a housing, an electric machine, a bracket, and a plurality of fasteners. The housing has internal rear and internal side walls that define a cavity. The electric machine stator and the bracket are disposed within the cavity. The bracket has a metallic inner ring and an elastomer outer ring. The elastomer outer ring engages the internal side wall. The electric machine stator is disposed between the bracket and the internal rear wall. The plurality of fasteners extends through the metallic inner ring, through the stator, and engages the rear internal wall to secure the stator to the housing.

Abstract: A vehicle transmission includes a housing, an electric machine stator, a support plate, and a plurality of fasteners. The housing has an internal rear wall and a side wall that define a cavity. The electric machine stator is disposed within the cavity. The support plate is disposed within the cavity. The support plate engages the internal side wall such that a press-fit engagement is formed between the support plate and the internal side wall. The electric machine is disposed between the support plate and the internal rear wall. The plurality of fasteners extends through the support plate, through the stator, and engages the rear internal wall to secure the stator to the housing.

Abstract: A vehicle transmission includes a housing, an electric machine stator, a support plate, and a plurality of fasteners. The housing has an internal rear wall and a side wall that define a cavity. The electric machine stator is disposed within the cavity. The support plate is disposed within the cavity. The support plate engages the internal side wall such that a press-fit engagement is formed between the support plate and the internal side wall. The electric machine is disposed between the support plate and the internal rear wall. The plurality of fasteners extends through the support plate, through the stator, and engages the rear internal wall to secure the stator to the housing.

Abstract: A vehicle transmission includes a housing, an electric machine, a bracket, and a plurality of fasteners. The housing has internal rear and internal side walls that define a cavity. The electric machine stator and the bracket are disposed within the cavity. The bracket has a metallic inner ring and an elastomer outer ring. The elastomer outer ring engages the internal side wall. The electric machine stator is disposed between the bracket and the internal rear wall. The plurality of fasteners extends through the metallic inner ring, through the stator, and engages the rear internal wall to secure the stator to the housing.

Abstract: A vehicle axle includes a housing, differential gearing, and a first clutch. The housing defines first and second cavities. The housing also defines a channel extending between the first and second cavities. The differential gearing is disposed within the first cavity and has a carrier extending into the second cavity. The first clutch is disposed within the second cavity. The first clutch is configured to selectively couple a half-shaft to the carrier. The first clutch has friction plates that include fanned spokes positioned to draw fluid from the channel and into the second cavity.

Abstract: A vehicle axle includes a housing, differential gearing, and a first clutch. The housing defines first and second cavities. The housing also defines a channel extending between the first and second cavities. The differential gearing is disposed within the first cavity and has a carrier extending into the second cavity. The first clutch is disposed within the second cavity. The first clutch is configured to selectively couple a half-shaft to the carrier. The first clutch has friction plates that include fanned spokes positioned to draw fluid from the channel and into the second cavity.

Abstract: A powertrain includes a transmission case, a transfer case, a front axle housing, and a webbed brace. The transfer case and front axle housing are directly fastened to the transmission case. The webbed brace is directly fastened to the transmission case, the transfer case, and the front axle housing to form a powerplant system. The webbed brace is configured such that a bending frequency of the powerplant system falls within a predefined range.

Abstract: A clutch assembly includes a first clutch assembly having first clutch plates rotatably fixed to a first shaft and first carrier plates rotatably fixed to a clutch basket. The clutch assembly further includes a second clutch assembly having second clutch plates rotatably fixed to a second shaft and second carrier plates rotatably fixed to the clutch basket. The first and second clutch assemblies rotate about a common central axis and are actuated by a common actuator.

Abstract: A multiple-stage ball ramp actuator includes an axially movable outer ring having at least one outer groove and an outer ball disposed in the outer groove. The multiple-stage ball ramp actuator further includes an axially movable inner ring rotatably fixed relative to the outer ring. The inner ring has at least one inner groove and an inner ball disposed in the inner groove.

Abstract: A multiple-stage ball ramp actuator includes an axially movable outer ring having at least one outer groove and an outer ball disposed in the outer groove. The multiple-stage ball ramp actuator further includes an axially movable inner ring rotatably fixed relative to the outer ring. The inner ring has at least one inner groove and an inner ball disposed in the inner groove.

Abstract: A clutch assembly includes a first clutch assembly having first clutch plates rotatably fixed to a first shaft and first carrier plates rotatably fixed to a clutch basket. The clutch assembly further includes a second clutch assembly having second clutch plates rotatably fixed to a second shaft and second carrier plates rotatably fixed to the clutch basket. The first and second clutch assemblies rotate about a common central axis and are actuated by a common actuator.

Abstract: A powertrain includes a transmission case, a transfer case, a front axle housing, and a webbed brace. The transfer case and front axle housing are directly fastened to the transmission case. The webbed brace is directly fastened to the transmission case, the transfer case, and the front axle housing to form a powerplant system. The webbed brace is configured such that a bending frequency of the powerplant system falls within a predefined range.