A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

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.

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.

An axle assembly having a pair of axle half shafts and an axle housing defining a sump. The axle assembly further includes a first clutch assembly including a first half and a second half, wherein the first half is selectively engaged to the second half. The axle assembly also includes a second clutch assembly disposed adjacent to the first clutch assembly, wherein the second clutch includes a gear and the gear is selectively engaged with the second half of the first clutch assembly. Yet further, the axle assembly includes a lubrication pump mounted in the axle housing and drivingly coupled to the second clutch assembly; a spring mounted between the first half and the second half of the first clutch assembly; and a bearing disposed between the spring and the second half of the first clutch assembly.

An axle assembly having a pair of axle half shafts and an axle housing defining a sump. The axle assembly further includes a first clutch assembly including a first half and a second half, wherein the first half is selectively engaged to the second half. The axle assembly also includes a second clutch assembly disposed adjacent to the first clutch assembly, wherein the second clutch includes a gear and the gear is selectively engaged with the second half of the first clutch assembly. Yet further, the axle assembly includes a lubrication pump mounted in the axle housing and drivingly coupled to the second clutch assembly; a spring mounted between the first half and the second half of the first clutch assembly; and a bearing disposed between the spring and the second half of the first clutch assembly.

A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

An axle assembly having a drive pinion and a bearing support wall. Lubricant in a shift mechanism housing may flow through a drive pinion passage in the drive pinion to return to a sump portion of an axle housing. The bearing support wall may include one or more lubricant passages.

An axle assembly having an electric motor module and a terminal box that may facilitate mounting of at least one phase cable. The phase cable may be secured to a terminal box cover with a terminal box clamp. The phase cable may extend through a phase block that may be mounted to the terminal box.