A modular electric axle head assembly for a vehicle. An axle assembly of the vehicle includes a banjo portion with a first opening extending from an inner surface to an outer surface of an inboard side of the banjo portion. At least a portion of a differential assembly disposed within at the banjo portion of the axle assembly and is drivingly connected to at least a portion of a gear assembly. The gear assembly is also drivingly connected to a motor output shaft. At least a portion of the gear assembly is disposed within a hollow portion of a gear assembly housing. An outboard portion of the gear assembly housing has a mounting flange that is integrally connected to the inboard side of the banjo portion. A first and second protruding portion extends from the axle assembly mounting flange and provides rotational support for the differential assembly.

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 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 differential includes a unitized double row angular contact ball bearing supporting a pinion stub shaft. The bearing includes two inner rings which are slightly separated before assembly. As the stub shaft is inserted into the bearing, one of the inner rings is pushed against a land such as the back of the pinion gear. Pushing the inner rings together ensures a suitable pre-load. The inner rings have an interference fit with the stub shaft such that friction maintains the pre-load without a nut. The bearing and shaft are then inserted between halves of a two-piece case.

An axle assembly with a housing, an annular gear, a bearing, a differential, and a pair of output shafts. The housing has an annular hub. The annular gear is received in the housing. The bearing, which is a four-point angular contact bearing, supports the gear for rotation about an axis relative to the housing and has an inner bearing race, which is mounted on the annular hub, and an outer bearing race that is fixedly coupled to the annular gear. The differential is received in the housing and includes an input member, which is coupled to the annular gear for rotation therewith, and a pair of output members that are rotatable relative to the input member about the output axis. Each of the output shafts is coupled to an associated one of the output members for rotation therewith. One of the output shafts extends through the annular hub.

An axle assembly having an electric motor module, a drive pinion, a planetary gear set, and at least one one-way freewheel clutch. The planetary gear set may operatively connect the electric motor module and the drive pinion. The one-way freewheel clutch may be configured to selectively couple at least two components of the planetary gear set.

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 transmission device includes a power-transmission case having a carrier of a reduction gear and a differential case joined to the carrier is supported in a transmission case via case support bearings, a specific planetary gear portion of a planetary gear is disposed on one side of a differential mechanism in an axial direction, and the specific case support bearing is disposed on the other side thereof An oil passage-forming body is provided on an inner wall of the transmission case, the oil passage-forming body comprising an oil collection part that opens upward and can collect lubricating oil splashed up in an area around the specific planetary gear portion within the transmission case accompanying rotation of the power-transmission case, and an oil reservoir part that is continuous from the oil collection part, stores lubricating oil collected by the oil collection part, and supplies the lubricating oil to the specific case support bearing.

A drive unit assembly including a differential assembly. The differential assembly includes a ring gear including an annular flange portion having an inner face and a differential case having an inner face configured to cooperate with the inner face of the annular flange portion of the ring gear. The differential case is configured to receive a spider therein, wherein the spider includes a main body including center bore formed therein, and wherein the center bore is configured to receive at least one output shaft therethrough.