A method of machining a carrier housing for an axle assembly comprises obtaining a carrier housing including circumferentially spaced apart tabs and positioning a datum setting tool in engagement with the carrier housing. The carrier housing is clamped to a fixture to position the carrier housing at a first orientation relative to a coordinate system within a work cell. The datum setting tool is disengaged from the carrier housing. Portions of the carrier housing along a first side are machined to define features including a carrier mounting flange and a cylindrical bearing bore extending perpendicular to the carrier mounting flange while the carrier housing remains clamped at the first orientation. Different portions of the carrier housing, on a second opposite side of the carrier housing, are machined to define additional geometrical feature while the initial clamped orientation continues to be maintained.

A differential apparatus includes a differential unit and a multi-plate clutch. The differential unit includes a differential case, a differential gear and a pair of output gears. The differential case includes a case main body and a cover body to close an opening of the case main body. The opening of the case main body is formed on a side of one of the pair of output gears. The multi-plate clutch is provided only on a side of the opening of the case main body. Outer clutch plates of the multi-plate clutch are engaged with the differential case. Inner clutch plates of the multi-plate clutch are engaged with the one of the pair of the output gears.

A transmission may have an input shaft, a first output shaft, a second output shaft, and an integral differential functionally located between the input shaft and the two output shafts. The transmission may have a planetary gearset that has one or more gearset elements, and a spur gearset, which has a first spur gear and second spur gear that are intermeshed, where a first gearset element is connected to the input shaft for conjoint rotation, where a second gearset element is connected to the first output shaft for conjoint rotation, where a third gearset element is at least indirectly connected to first spur gear for conjoint rotation, and where the second spur gear is at least indirectly connected to the second output shaft for conjoint rotation.

A transmission may have an input shaft, a first output shaft, a second output shaft, and an integral differential functionally located between the input shaft and the two output shafts. The transmission may have a planetary gearset that has one or more gearset elements, and a spur gearset, which has a first spur gear and second spur gear that are intermeshed, where a first gearset element is connected to the input shaft for conjoint rotation, where a second gearset element is connected to the first output shaft for conjoint rotation, where a third gearset element is at least indirectly connected to first spur gear for conjoint rotation, and where the second spur gear is at least indirectly connected to the second output shaft for conjoint rotation.

A differential assembly include a housing defining an oil sump, a differential disposed in the housing, and a thermal-management system. The system includes an oil pump in fluid communication with the sump, a spool valve having an inlet connected to the pump, a first outlet, a second outlet, and a spool slidable to a first position in which the inlet is in fluid communication with the first outlet and to a second position in which the inlet is in fluid communication with the second outlet. The spool valve further has a chamber containing wax configured to move the spool according to a temperature of the wax such that the spool is in the first position when the temperature of the wax is within a first temperature range and is in the second position when the temperature of the wax is within a second temperature range.

A differential assembly include a housing defining an oil sump, a differential disposed in the housing, and a thermal-management system. The system includes an oil pump in fluid communication with the sump, a spool valve having an inlet connected to the pump, a first outlet, a second outlet, and a spool slidable to a first position in which the inlet is in fluid communication with the first outlet and to a second position in which the inlet is in fluid communication with the second outlet. The spool valve further has a chamber containing wax configured to move the spool according to a temperature of the wax such that the spool is in the first position when the temperature of the wax is within a first temperature range and is in the second position when the temperature of the wax is within a second temperature range.

A thrust washer and a differential containing a thrust washer. The differential has a housing, a spider with a plurality of spider arms, and one or more spider gears. The thrust washer includes a body comprising an annular shape having a width configured to approximately match a width of the one or more spider gears and further configured to a have a slope along the width configured to conform with an inner diameter of the housing and at least one engagement mechanism to engage with at least two of the plurality of spider arms to engage the thrust washer with the spider to approximately prevent the thrust washer from rotating relative to the housing when the thrust washer is installed in the differential.

A thrust washer and a differential containing a thrust washer. The differential has a housing, a spider with a plurality of spider arms, and one or more spider gears. The thrust washer includes a body comprising an annular shape having a width configured to approximately match a width of the one or more spider gears and further configured to a have a slope along the width configured to conform with an inner diameter of the housing and at least one engagement mechanism to engage with at least two of the plurality of spider arms to engage the thrust washer with the spider to approximately prevent the thrust washer from rotating relative to the housing when the thrust washer is installed in the differential.

A modified differential internal system for a vehicle differential may include a preexisting ring gear having a perimeter. The system may include a ring gear sleeve having a thickness, the ring gear sleeve being affixed to the ring gear perimeter. The system may include a spring retainer having a first surface and a second surface, the first surface having a first set of lugs and the second surface having a second set of lugs. The system may include an armature plate having a plurality of slots configured to engage the first set of lugs, and a sprag plate having a plurality of slots configured to engage the second set of lugs. The sprag plate may have a plurality of locking tabs configured to engage a sprag cage of the vehicle differential.

A modified differential internal system for a vehicle differential may include a preexisting ring gear having a perimeter. The system may include a ring gear sleeve having a thickness, the ring gear sleeve being affixed to the ring gear perimeter. The system may include a spring retainer having a first surface and a second surface, the first surface having a first set of lugs and the second surface having a second set of lugs. The system may include an armature plate having a plurality of slots configured to engage the first set of lugs, and a sprag plate having a plurality of slots configured to engage the second set of lugs. The sprag plate may have a plurality of locking tabs configured to engage a sprag cage of the vehicle differential.