Dana Corporation

Dana Heavy Vehicle Systems Group, LLC

Arvin Meritor Technology, LLC

Leo Wenstrup

Gary Turner

Dale L Kwasniewski

Steve G Slesinski

James Foltan Ziech

Stephen P Claussen

David Owen Thompson

Francisco Garcia

Matthew Neff

James Alden Beverly

Andrew Bodary

Michael Green, Jr

Glen David Peterson

Leonard P Stoehr

Chris Pollack

Tim Mann

An axle assembly that has a lubricant reservoir. The lubricant reservoir may be disposed above a differential assembly and may capture lubricant that is splashed by the differential assembly. The lubricant reservoir may have at least one tank. The lubricant reservoir may optionally provide lubricant to a lubricant distribution trough.

Axle assembly having a lubricant reservoir

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.

Ribbed cover for drive axle housing

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.

Output yoke shaft and assembly

The present invention comprises a breather system and a method of using the system. The assembly has a breather tube, a baffle system at least partially located within the breather tube and a drain back tube connected to the breather tube. The baffle system has a plurality of baffles designed to prevent lubricant from escaping a housing while still allowing air to pass into and out of the housing.

Breather system and method of using the same

A method for converting a non-driven tag axle system to a driven axle system is disclosed where a forward driven axle system is converted to drive an interaxle drive shaft. The interaxle drive shaft is connected to a drive axle head mounted within the tag axle housing. Drive axles are connected to drive axle head. In another embodiment, a forward driven axle system is removed from a first position on the vehicle frame and the tag axle is removed from a second position on the vehicle frame. A differential is installed in the tag axle and it is located in the first position. The forward driven axle system is located in the second position and connected to the differential in the first position.

Method for converting a non-driven tag axle system to a driven axle system

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.

Inter-axle differential lock shift mechanism

An actuation enhancement for an automated vehicle inter-axle differential (IAD) locking system. The vehicle having an engine and a tandem drive axle. The IAD actuation enhancement locking system comprises a rotating sliding clutch and a rotating side helical gear, which are capable of an engagement mode and a disengagement mode, a microprocessor, and an electrical connection between the microprocessor and an engine electronic control unit. When the sliding clutch and the helical gear are placed in the engagement mode or are placed in the disengagement mode, the microprocessor momentarily communicates a data link message to the engine electronic control unit to break engine torque, to facilitate engagement or disengagement of the sliding clutch and the helical gear.

Automated inter-axle differential locking system actuation enhancement

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.

Enhanced lubrication system for drive axle assemblies

The present invention relates to an automatic inter-axle differential lock actuation sensing method for a vehicle having a tandem drive axle. The inter-axle differential lock actuation sensing method comprises providing a clutch locking mechanism of an inter-axle differential for a vehicle, the clutch locking mechanism having a first set of teeth in a fixed position and a second set of teeth on a sliding clutch, locating a speed sensor such that when the clutch mechanism is disengaged the sensor measures a speed of the sliding clutch, and when the clutch mechanism is fully engaged the sensor measures zero speed even though the sliding clutch continues to rotate, providing a speed of the vehicle from a vehicle data link, and using the speed sensor-speed and the vehicle speed to determine status of clutch mechanism engagement.

Automated inter-axle differential lock actuation sensing method

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.

Bolted pilot web with precision machined bearing stop

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.

Pinion support for a differential assembly

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.

Differential with pinion bearings supported on input yoke

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.

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Portage, MI, United States of America

Leo Wenstrup