In at least one implementation, a method of assembling gears into a housing of an automotive differential includes, selecting a thickness dimension of first and second pinion gear washers, and first and second side gear washers, locating a pair of pinion gears, a pinion shaft and a pair of side gears at least partially within an interior of the housing with the pinion gear washers between the housing and separate ones of the pinion gears, and the side gear washers between the housing and separate ones of the side gears. The thickness of the side gear washers may be a function of target side gear apex positions and relative to a pinion gear apex axis. The thickness of the pinion gear washers may be a function of target pinion gear apex positions residing along a pinion gear apex axis and relative to a side gear apex axis.

A member joining structure for a differential device, the member joining structure includes a ring gear including a helical tooth extending in a rotation axis direction; a differential case that is rotated with the ring gear; and a first support that is disposed in a first position at a back surface corresponding to one end of a rotation axis of the ring gear and that connects the differential case and the ring gear, and a second support that is disposed in a second position at a back surface corresponding to another end in the rotation axis direction of the ring gear and that connects the differential case and the ring gear; wherein the first support and the second support are spaced apart from each other with a cavity therebetween.

An axle assembly and a method of assembly. The axle assembly has a drive pinion, a through shaft, and at least one support bearing. The through shaft may extend through a drive pinion passage that may extend through the drive pinion. One or more support bearings may be disposed in the drive pinion passage and may rotatably support the drive pinion.

A method for joining a carburized steel workpiece to a cast iron workpiece is provided that includes tempering a localized area of the carburized steel workpiece, machining the localized area to reduce carbon content, and welding the carburized steel workpiece to the cast iron workpiece at the localized area. The tempering may be performed by induction heating and results in a hardness profile of the localized area of less than 50 HRC.

A system for making a welded assembly. The system may include a welding system that is configured to weld a first part to a second part with a laser beam. The system may further include an integrated feeder nozzle that includes an inlet manifold that receives a shield gas, and a nozzle body secured to the inlet manifold. The nozzle body may include a plurality of peripheral apertures that extend through the conical distal region and that are arranged around a central axis of the nozzle body. The system may further include a wire feeder disposed in the inlet manifold and the nozzle body. The wire feeder receives a welding wire and guides the welding wire to the central aperture.

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 drive device for a motor vehicle, includes a differential gearing and a torque vectoring unit having an electric machine, wherein the differential gearing has a first and a second planet set, which are rotatably supported on a common planet carrier, wherein the first planet set meshes at least with a first sun, the second planet set meshes at least with a second sun, and the two planet sets at least mesh with each other in pairs, and wherein at least the second sun is connected to the torque vectoring unit in order to redistribute the torque between the first and the second suns.

A differential gear assembly, in particular for a motor vehicle, includes a gearwheel, driven by a pinion and arranged on a differential case that is rotatably mounted in a gearbox case via rolling-contact bearings on both sides. Planet gears are supported in the differential case on at least one driving pin and meshing with axis-parallel output gears on output half-shafts. The gearwheel is attached to the differential case without form fit in circumferential direction and has recesses into which the at least one driving pin formfittingly projects in circumferential direction.

A vehicle differential assembly includes a differential housing including an outer surface and a driveshaft mounting end having a terminal end portion. A differential gear set is rotationally supported within the differential housing. A pinion gear is arranged in the differential housing. The pinion gear includes a head end drivingly connected to the differential gear set and a tail end extending through the driveshaft mounting end. A head bearing is arranged within the driveshaft mounting end. The head bearing supports the head end of the pinion gear. A tail bearing is supported by the outer surface of the differential housing. The tail bearing is configured and disposed to support the tail end of the pinion relative to the driveshaft mounting end.

A mounting system for a differential comprises a cross shaft. The cross shaft comprises a passageway through the cross shaft perpendicular to a long axis. The passageway comprises a first hole and a second hole. A recess comprising a planar wall is proximal to the first hole. A first stub shaft comprises a planar surface in contact with the planar wall. A second stub shaft is proximal the second hole. A yoke in the passageway comprises a first portion extending in to the first stub shaft and a second portion extending in to the second stub shaft. A first bang ring is on the first portion of the yoke, and a second bang ring is on the second portion of the yoke. The yoke slip fits to the first stub shaft and the yoke slip fits to the second stub shaft.