A manufacturing method for a power transmission mechanism including: first and second shafts having first and second double helical gears; first and second rolling bearings rotatably supporting the shafts with respect to a case and restrict movement of the shafts in an axial direction thereof, includes an assembling step of assembling an outer ring of the first rolling bearing and an outer ring of the second rolling bearing to the case in a state where the outer rings are movable in the respective axial directions; and a positioning step of determining axial positions of the first rolling bearing and the second rolling bearing while rotating the first shaft and the second shaft in a state where the first double helical gear and the second double helical gear are meshed with each other, after the assembling step.

An axle assembly that includes a first gear mechanism, a second gear mechanism, and a differential assembly. The first gear mechanism and the differential assembly may be rotatable about a first axis. The second gear mechanism may be rotatable about a second axis. Torque may be transmitted between the first gear mechanism and the differential via the second gear mechanism.

An axle assembly having an electric motor module, a drive pinion, and at least one rotor bearing assembly. The electric motor module may have a rotor. The rotor and the drive pinion may be rotatable about a first axis. The first rotor bearing assembly may extend between the drive pinion and the rotor.

A differential drive system includes an electric motor for generating an electric motor torque and an input planetary gear-set operatively connected to the electric motor to receive the electric motor torque. The input planetary gear-set has first, second, and third members. The first member receives the electric motor torque, the second member provides a first input torque in a first rotational direction in response to the electric motor torque, and the third member provides a second input torque in a second rotational direction, opposite the first direction, in response to the electric motor torque. The system also includes a first output gear-set operatively connected to the input planetary gear-set, and providing a first output torque in response to the first input torque. The system additionally includes a second output gear-set operatively connected to the input planetary gear-set and providing a second output torque in response to the second input torque.

A differential drive system includes an electric motor for generating an electric motor torque and an input planetary gear-set operatively connected to the electric motor to receive the electric motor torque. The input planetary gear-set has first, second, and third members. The first member receives the electric motor torque, the second member provides a first input torque in a first rotational direction in response to the electric motor torque, and the third member provides a second input torque in a second rotational direction, opposite the first direction, in response to the electric motor torque. The system also includes a first output gear-set operatively connected to the input planetary gear-set, and providing a first output torque in response to the first input torque. The system additionally includes a second output gear-set operatively connected to the input planetary gear-set and providing a second output torque in response to the second input torque.

An axle assembly having a spigot bearing assembly. The spigot bearing assembly may extend between a motor housing and a rotor output flange that may be fixedly mounted to a rotor. The spigot bearing assembly may rotatably support the rotor output flange and may inhibit deflection of the rotor. A spigot bearing biasing member may exert a biasing force on the spigot bearing assembly.

An axle assembly having a spigot bearing assembly. The spigot bearing assembly may extend between a motor housing and a rotor output flange that may be fixedly mounted to a rotor. The spigot bearing assembly may rotatably support the rotor output flange and may inhibit deflection of the rotor. A spigot bearing biasing member may exert a biasing force on the spigot bearing assembly.

A differential device may include a housing having an inner surface and an outer surface, said inner surface having an outer ring gear and said outer surface having a first receptacle and a sun gear positioned within the housing, the sun gear having a second receptacle positioned opposite the first receptacle. The differential device may further include an intermediate gear interposed between the sun gear and the outer ring gear, a bearing interposed between the inner surface of the housing and the sun gear, and a central axis intersecting the first receptacle and the second receptacle. The housing and the sun gear may be configured to rotate freely about the central axis.

A differential device may include a housing having an inner surface and an outer surface, said inner surface having an outer ring gear and said outer surface having a first receptacle and a sun gear positioned within the housing, the sun gear having a second receptacle positioned opposite the first receptacle. The differential device may further include an intermediate gear interposed between the sun gear and the outer ring gear, a bearing interposed between the inner surface of the housing and the sun gear, and a central axis intersecting the first receptacle and the second receptacle. The housing and the sun gear may be configured to rotate freely about the central axis.

A method for assembling an axle assembly for a vehicle including that a pinion gear is inserted into a differential housing. The pinion gear having a first end and a second end opposite the first end. The pinion gear further includes a gear head at the first end, external threads proximate the second end, and external splines located a first distance away from the second end. The method further includes that a flange is slid over the second end of the pinion gear. The flange including internal splines. The method also includes that the internal splines of the flange are engaged with the external splines of the pinion gear and the flange is anchored to prevent the flange and the pinion gear from rotating. The method may further include that ultrasonic sound waves are transmitted through the pinion gear and reflections of the ultrasonic sound waves are detected.