A thrust washer and a differential containing a thrust washer. The differential has a housing, a spider and one or more spider gears. The thrust washer includes a body having an annular shape and a width configured to approximately match with a width of the one or more spider gears. The thrust washer is further configured to engage with the spider to prevent or reduce 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 and one or more spider gears. The thrust washer includes a body having an annular shape and a width configured to approximately match with a width of the one or more spider gears. The thrust washer is further configured to engage with the spider to prevent or reduce the thrust washer from rotating relative to the housing when the thrust washer is installed in the differential.

A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.

A method of fusion welding two ferrous alloy component parts, at least one of which is considered unweldable, involves placing a low carbon steel band into a groove defined in part by each of the ferrous alloy component parts and then conveying a concentrated energy source along a welding line that overlaps the low carbon steel band to melt the steel band along with adjacent portions of the ferrous alloy component parts to form a blended alloy weld pool. The blended alloy weld pool solidifies behind the forward movement of the concentrated energy source into a weld joint that fusion welds the ferrous alloy component parts together. The ferrous alloy component parts may include a differential casing and a ring gear. In that regard, a differential casing and ring gear assembly that includes a weld joint is also disclosed.

A differential gear assembly for a vehicle includes: an annular ring gear having internal and external surfaces, and rotates around a rotational axis extending in an axial direction; first and second side gears respectively distribute a first and second output torque to first and second drive shafts; first and second differential pinion gears respectively engage the first and second side gears; a pinion pin extends diametrically across the ring gear, where the first and second differential pinion gears are rotatably arranged on the pinion pin. The ring gear comprises first and second slots for receiving the pinion pin, where the slots are arranged in connection to the internal surface and extend partly through the ring gear in the axial direction.

A differential gear assembly for a vehicle includes: an annular ring gear having internal and external surfaces, and rotates around a rotational axis extending in an axial direction; first and second side gears respectively distribute a first and second output torque to first and second drive shafts; first and second differential pinion gears respectively engage the first and second side gears; a pinion pin extends diametrically across the ring gear, where the first and second differential pinion gears are rotatably arranged on the pinion pin. The ring gear comprises first and second slots for receiving the pinion pin, where the slots are arranged in connection to the internal surface and extend partly through the ring gear in the axial direction.

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 conversion kit for replacing a bottom-mounted differential with a top-mounted differential using pre-existing mounting features of a vehicle. The kit includes a pair of support members, a pair of mounting gussets, a support plate, and a skid plate. The support members are coupled along top side edges of the top-mounted differential. The support members are coupled to forward and rearward frame members within a differential cavity of a vehicle using the mounting gussets and tabs on the support members and using fasteners installed in pre-existing mounting holes in the vehicle. The top-mounted differential is positioned to maintain substantially the same location and orientation of couplings with a drive train of the vehicle as those used by the bottom-mounted differential. The support plate extends between the support members and optionally supports a winch. The skid plate encloses a clearance opening formed in a pre-existing armor plate of the vehicle.

A conversion kit for replacing a bottom-mounted differential with a top-mounted differential using pre-existing mounting features of a vehicle. The kit includes a pair of support members, a pair of mounting gussets, a support plate, and a skid plate. The support members are coupled along top side edges of the top-mounted differential. The support members are coupled to forward and rearward frame members within a differential cavity of a vehicle using the mounting gussets and tabs on the support members and using fasteners installed in pre-existing mounting holes in the vehicle. The top-mounted differential is positioned to maintain substantially the same location and orientation of couplings with a drive train of the vehicle as those used by the bottom-mounted differential. The support plate extends between the support members and optionally supports a winch. The skid plate encloses a clearance opening formed in a pre-existing armor plate of the vehicle.