Borgwarner Inc.

Stephen D Tucker

Travis J Wentz

Mallikarjun Rudagi

Abhinav Jain

Thad S Morton

Michael Whitaker

Bo Yang

Robert Harris

A transfer case with an actuator for operating a two-speed transmission (i.e., range mechanism) and a clutch (i.e., mode mechanism). The actuator employs a motor-driven cam structure that coordinates the movement of a first fork, which is associated with the range mechanism, and a second fork that is associated with the mode mechanism. A resilient coupling is employed to provide compliance between the motor and the cam structure in the event that tooth-on-tooth contact inhibits the range mechanism from changing from a high-range mode and a low range mode. Compliance is provided between the cam structure and the second fork in the event that tooth-on-tooth contact inhibits the mode mechanism from changing from aWD mode to aWD mode. A sensor system identifies the placement of the first and second forks in various positions and responsively generates associated sensor signals.

Transfer case with range and mode actuator having cam follower mechanism to overcome blocked shift events and sensor configuration permitting detection of fork positions

A transfer case for a normally rear wheel drive vehicle with selective four wheel drive capabilities is provided. The transfer case has an intermediate gear driven lubrication pump, wherein the machining required for the lubrication pump is almost exclusively conducted from an interior side of the rear shell. The transfer case of the present invention also eliminates the requirement for a cover plate for the pump and an external lubrication tube. The transfer case of the current invention has an internal lubrication pump outlet which has a portion extending in a reinforcing mound of the rear shell thereby providing greater stiffness to a portion of the rear shell supporting the main input shaft rear bearings.

Tubeless lubrication delivery system for a compact transfer case

Growing community of inventors

Muncie, IN, United States of America

Stephen D Tucker