In a differential device in which a working window is provided in a case main body of a differential case that can rotate around a first axis, when viewed on the projection plane, orthogonal to the first axis, among joining parts between a flange portion of the differential case and a ring gear, a specific joining part that is the closest to the working window is positioned further outward than an inner end part of the working window in a direction along a third axis orthogonal to the first axis and a pinion axis, and the working window is positioned further outward, in the direction along the third axis, than an imaginary straight line joining the specific joining part and the first axis. Accordingly, rigidity strength of the differential case is enhanced and concentration of stress is prevented from occurring in the working window of the case main body.

A differential gear assembly, and method for assembling such an assembly are provided. The differential gear assembly comprises a housing constructed of substantially identically shaped and sized housing plates, which each have an outer flange of a same diameter. The assembly further comprises an outer helical ring gear that is fixed to the housing, wherein outer helical ring gear comprises an inner flange for mounting to the outer flange of the first or second housing plate, wherein an inner diameter of the inner flange is smaller than the outer diameter of the housing plates. The inner flange of the helical ring gear can thus be held, e.g. clamped, between the outer flanges of the housing plates. In an alternative embodiment, the outer flange of one of the housing plates is held between the inner flange of the ring gear and the outer flange of the other of the housing plates.

The differential device measuring tool measures an inflow amount of lubricating oil flowing into a housing space through a communication hole during the rotation of a differential case having a case main body in which the housing space and the communication hole are formed and a bearing boss having a through-hole protruding from the case main body and communicating with the housing space. The measuring tool has a collecting portion and a deriving portion. The collecting portion does not interfere with the rotating differential case in the housing space in which the differential gear mechanism is not housed, and has a recess opening and collects the lubricating oil flowing into the housing space through the communication hole. The deriving portion is inserted through the through-hole of the bearing boss and have a deriving flow channel. The deriving flow channel communicates with the recess, and extends to the outside.

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.

Methods and systems for estimating an amount of torque that is transferred via a differential ring gear assembly are described. In one example, axial displacement of the differential ring gear assembly is determined and converted into a torque estimate. The torque estimate may be used to verify other powertrain torque estimates or for closed loop torque control.

A differential assembly includes a first case rotatable about an axis and defining a first mounting flange having a through hole and a second case abutting the first case to define a gear nest cavity therebetween. The second case further defines a second mounting flange having a through hole and formed to mate to the first mounting flange. The differential assembly also includes a ring gear mounted to the first mounting flange and fastener extending through the through hole of both the first mounting flange and second mounting flange into a fastener hole of the ring gear. Additionally, the first mounting flange is sandwiched between the second mounting flange and the ring gear.

A differential assembly includes a first case rotatable about an axis and defining a first mounting flange having a through hole and a second case abutting the first case to define a gear nest cavity therebetween. The second case further defines a second mounting flange having a through hole and formed to mate to the first mounting flange. The differential assembly also includes a ring gear mounted to the first mounting flange and fastener extending through the through hole of both the first mounting flange and second mounting flange into a fastener hole of the ring gear. Additionally, the first mounting flange is sandwiched between the second mounting flange and the ring gear.

Various improvements to axle assemblies are disclosed herein that are especially adapted for highly robust and compact configurations for use in front (i.e., steering) axle configurations.

A differential assembly includes a differential, a collar, and a coupling. The differential has a differential input and differential gearing. The differential input is rotatable about a differential axis. The differential gearing has first and second differential output gears that are rotatable relative to the differential input about the differential axis. The differential gearing transmits rotary power between the differential input and the first and second differential output gears. The collar is rotatable about the differential axis. The coupling has first and second coupling members. The first coupling member is fixedly coupled to the first side gear. The second coupling member is fixedly coupled to the collar. The coupling is operable in a disengaged mode, in which the collar is rotationally decoupled from the first differential output gear, and an engaged mode in which the collar is rotatably coupled to the first differential output gear.

A differential assembly includes a differential, a collar, and a coupling. The differential has a differential input and differential gearing. The differential input is rotatable about a differential axis. The differential gearing has first and second differential output gears that are rotatable relative to the differential input about the differential axis. The differential gearing transmits rotary power between the differential input and the first and second differential output gears. The collar is rotatable about the differential axis. The coupling has first and second coupling members. The first coupling member is fixedly coupled to the first side gear. The second coupling member is fixedly coupled to the collar. The coupling is operable in a disengaged mode, in which the collar is rotationally decoupled from the first differential output gear, and an engaged mode in which the collar is rotatably coupled to the first differential output gear.