A differential assembly arrangement with optimized pinion shaft bearing lubrication is provided. The assembly includes a housing, a ring gear, a pinion gear, a pinion shaft supported by two rolling element bearings, a sleeve, and a lubrication deflector. The two rolling element bearings, a pinion head bearing bearing and a pinion tail bearing, are located at each end of the sleeve which fits over the pinion shaft. The sleeve helps facilitate the application of a pre-load to the bearings. The lubrication deflector is located along the length of the sleeve for providing the correct amount of lubricant to the two bearings. The deflector is in the form of a ring located on the sleeve or integrated within the sleeve.

Methods and systems are provided for an electric axle assembly. In one example, a system, includes a cover plate for a head assembly, wherein a cross-member is integrated into the cover plate and configured to attach to a vehicle frame.

An axle assembly having an axle housing, an axle shaft, a plurality of axle shaft bearings and a seal. The axle housing has a tubular member and an end flange that is coupled to the tubular member. The axle shaft bearings and the seal are received in the end flange and are engaged to the axle shaft. The axle shaft bearings support the axle shaft for rotation relative to the axle housing. The seal is sealingly engaged to the end flange and the axle shaft. A method for assembling an axle assembly is also provided.

An electric axle is configured to selectively enable an electric motor to power a pair of drive shafts of a vehicle. The electric axle includes a planetary gearset configured to drivably couple an electric motor with first and second drive shafts coaxially arranged. The planetary gearset including a ring gear. A housing at least partially surrounds the planetary gearset and is configured to be grounded to the vehicle. A clutch is configured to selectively ground the ring gear with the housing to enable an electric motor to power the first and second drive shafts. The electric axle may include a second planetary gearset, namely a differential planetary gearset. The differential planetary gearset may include a carrier that is shared or common amongst the planetary gearset and the differential planetary gearset.

An electric axle is configured to selectively enable an electric motor to power a pair of drive shafts of a vehicle. The electric axle includes a planetary gearset configured to drivably couple an electric motor with first and second drive shafts coaxially arranged. The planetary gearset including a ring gear. A housing at least partially surrounds the planetary gearset and is configured to be grounded to the vehicle. A clutch is configured to selectively ground the ring gear with the housing to enable an electric motor to power the first and second drive shafts. The electric axle may include a second planetary gearset, namely a differential planetary gearset. The differential planetary gearset may include a carrier that is shared or common amongst the planetary gearset and the differential planetary gearset.

A bi-directional overrunning clutch differential is configured to transmit power from an input shaft to a first output shaft and a second output shaft in a vehicle. The differential includes a differential housing having a first bearing seat and a second bearing seat. A first bearing is carried by the differential housing in the first bearing seat, and a second bearing is carried by the differential housing in the second bearing seat. A first retaining ring secures the first bearing in the first bearing seat, and a second retaining ring secures the second bearing in the second bearing seat. A first output hub is carried by the first bearing for rotation relative to the differential housing, and a second output hub is carried by the second bearing for rotation relative to the differential housing.

A method for joining components of a vehicle drive axle assembly. The method includes heating an axle housing to a first predetermined temperature and cooling a pinion cartridge to be installed with the housing to a second predetermined temperature. Removing the axle housing from exposure to the first predetermined temperature and removing the pinion cartridge from the second predetermined temperature and rapidly installing the pinion cartridge within the axle assembly before the axle assembly and the pinion return to ambient temperature provides a frictional fit, joining the two components without use of additional fastening devices.

A method for joining components of a vehicle drive axle assembly. The method includes heating an axle housing to a first predetermined temperature and cooling a pinion cartridge to be installed with the housing to a second predetermined temperature. Removing the axle housing from exposure to the first predetermined temperature and removing the pinion cartridge from the second predetermined temperature and rapidly installing the pinion cartridge within the axle assembly before the axle assembly and the pinion return to ambient temperature provides a frictional fit, joining the two components without use of additional fastening devices.

A pinion shaft assembly facilitates assembly of an automotive differential. An angular contact double row ball bearing is assembled to an outer surface of a hollow pinion shaft. An axial pre-load is established and maintained by orbitally forming an outwardly turned portion of the hollow pinion shaft. In some embodiments, the two inner rings are assembled to the pinion shaft. In other embodiments, a raceway may be formed directly on an outer surface of the pinion shaft to eliminate one of the inner rings. The pinion shaft includes a spline, such as an axial spline or a face spline, for fixation to a driveshaft.

A pinion shaft assembly facilitates assembly of an automotive differential. An angular contact double row ball bearing is assembled to an outer surface of a hollow pinion shaft. An axial pre-load is established and maintained by orbitally forming an outwardly turned portion of the hollow pinion shaft. In some embodiments, the two inner rings are assembled to the pinion shaft. In other embodiments, a raceway may be formed directly on an outer surface of the pinion shaft to eliminate one of the inner rings. The pinion shaft includes a spline, such as an axial spline or a face spline, for fixation to a driveshaft.