Axle assembly includes first and second axle housings extending toward opposing sides of a vehicle frame with the axle housings aligned to define an axle axis, first and second wheel ends, first and second drive shafts disposed within the first and second axle housings, a gearbox having a first surface facing one side of the vehicle frame and a second surface facing the other side of the vehicle frame with the gearbox cantilevered outwardly relative to the aligned axle housings to define a gearbox axis parallel to a longitudinal axis of the vehicle frame and transverse to the axle axis, and an electric motor coupled to the second surface of the gearbox and extending toward the first side of the vehicle frame to define a motor axis that is parallel to and offset from the axle axis, transverse to the gearbox axis, and transverse to the longitudinal axis.

Axle assembly includes first and second axle housings extending toward opposing sides of a vehicle frame with the axle housings aligned to define an axle axis, first and second wheel ends, first and second drive shafts disposed within the first and second axle housings, a gearbox having a first surface facing one side of the vehicle frame and a second surface facing the other side of the vehicle frame with the gearbox cantilevered outwardly relative to the aligned axle housings to define a gearbox axis parallel to a longitudinal axis of the vehicle frame and transverse to the axle axis, and an electric motor coupled to the second surface of the gearbox and extending toward the first side of the vehicle frame to define a motor axis that is parallel to and offset from the axle axis, transverse to the gearbox axis, and transverse to the longitudinal axis.

A dual plunging constant velocity (CV) drive shaft is provided for communicating rotational forces from a transaxle to a drive wheel of a vehicle. The dual plunging CV drive shaft comprises a drive shaft that transfers torque from the transaxle to the drive wheel. An inboard plunging CV joint is coupled between the transaxle and the drive shaft, and an outboard plunging CV joint is coupled between the drive shaft and the drive wheel. The inboard and outboard plunging CV joints each comprises an elongate housing that receives a CV joint coupled with the drive shaft. The inboard and outboard plunging CV joints communicate rotational forces from the transaxle to the drive wheel during vertical pivoting of a trailing arm coupled with the outboard plunging CV joint. The elongate housings allow the drive shaft to “float” longitudinally, as needed, during extreme pivoting motion of the suspension.

A dual plunging constant velocity (CV) drive shaft is provided for communicating rotational forces from a transaxle to a drive wheel of a vehicle. The dual plunging CV drive shaft comprises a drive shaft that transfers torque from the transaxle to the drive wheel. An inboard plunging CV joint is coupled between the transaxle and the drive shaft, and an outboard plunging CV joint is coupled between the drive shaft and the drive wheel. The inboard and outboard plunging CV joints each comprises an elongate housing that receives a CV joint coupled with the drive shaft. The inboard and outboard plunging CV joints communicate rotational forces from the transaxle to the drive wheel during vertical pivoting of a trailing arm coupled with the outboard plunging CV joint. The elongate housings allow the drive shaft to “float” longitudinally, as needed, during extreme pivoting motion of the suspension.

An axle-shaft system for transmitting torque in a motor vehicle drive-train includes first and second two-stage stiffness axle-shafts. Each axle-shaft includes a hollow cylinder having first and second ends and a hollow cylinder stiffness. The axle-shaft also includes an inner shaft extending through the hollow cylinder, and having first and second ends and an inner shaft stiffness. The inner shaft's and the hollow cylinder's first ends are engaged via a rotational clearance fit. The inner shaft's and the hollow cylinder's second ends are rotationally fixed to permit the inner shaft's first end to twist relative to the inner shaft's second end. The inner shaft's stiffness defines the axle-shaft's first-stage stiffness, while the inner shaft's and the hollow cylinder's combined stiffness defines the axle-shaft's second-stage stiffness. At least one of the first-stage and second-stage stiffness of the first axle-shaft is dissimilar from the respective stiffness of the second axle-shaft.

An axle-shaft system for transmitting torque in a motor vehicle drive-train includes first and second two-stage stiffness axle-shafts. Each axle-shaft includes a hollow cylinder having first and second ends and a hollow cylinder stiffness. The axle-shaft also includes an inner shaft extending through the hollow cylinder, and having first and second ends and an inner shaft stiffness. The inner shaft's and the hollow cylinder's first ends are engaged via a rotational clearance fit. The inner shaft's and the hollow cylinder's second ends are rotationally fixed to permit the inner shaft's first end to twist relative to the inner shaft's second end. The inner shaft's stiffness defines the axle-shaft's first-stage stiffness, while the inner shaft's and the hollow cylinder's combined stiffness defines the axle-shaft's second-stage stiffness. At least one of the first-stage and second-stage stiffness of the first axle-shaft is dissimilar from the respective stiffness of the second axle-shaft.

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 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 vehicle axle (10), including: a left axle (12L), a first side thereof being pivotally connected (50L) to a left wheel hub (14L); a right axle (12R), a first side thereof being pivotally connected (50R) to a right wheel hub (14R); a connector (20), disposed between second sides of the left (12L) and right (12R) axles for pivotally (28) connecting therebetween, for allowing pivotal motion therebetween; a first mechanism (52A,52B) for allowing and disallowing the pivotal motion between the left (12L) and right (12R) axles.

A vehicle axle (10), including: a left axle (12L), a first side thereof being pivotally connected (50L) to a left wheel hub (14L); a right axle (12R), a first side thereof being pivotally connected (50R) to a right wheel hub (14R); a connector (20), disposed between second sides of the left (12L) and right (12R) axles for pivotally (28) connecting therebetween, for allowing pivotal motion therebetween; a first mechanism (52A,52B) for allowing and disallowing the pivotal motion between the left (12L) and right (12R) axles.