Transfer case assembly with a double duty differential

Claim 2

A transfer case assembly comprising a transfer case housing, an input shaft and two output shafts rotatably supported within said housing, a differential cross and a differential casing each rotatably supported within said housing, said differential cross including cross pin means, a pair of pinion gears and a pair of side gears disposed in said differential casing with said pinion gears each being rotatable on said pin means and with each of said pinion gears meshing with both of said side gears, gear locking means for selectively holding one of said side gears in a non-rotative relation to said housing and coupling means for selectively interconnecting said differential cross and housing to said three shafts for two modes of four-wheel drive operations, wherein one mode said coupling means connects: said cross pin to said input shaft, one of said side gears to one of said output shaft and the other of said side gears to the other of said output shafts, and wherein the other mode said gear locking means holds one of said side gears in a non-rotative position and said coupling means connects: the other of said side gears to said input shaft, said differential casing to one of said output shafts, and said cross pin to the other of said output shafts.

Claim 3

The Combination of claim 1, further comprising shifting means for selectively moving in unison said coupling means and said gear locking means such that in said one mode said one side gear is free to spin and in said other mode said gear locking means is moved in said holding position.

Claim 4

The combination of claim 2, wherein said coupling means comprises first, second and third coupler means carried by said shifting means for conjoint movement with said gear locking means, wherein said one mode of four-wheel drive operation said first coupler means connects said cross pin to said input shaft for rotation therewith, said second coupler means connects one of said side gears to one of said output shafts for rotation therewith and said third coupler means connects the other of said side gears to the other of said output shafts for rotation therewith, and wherein said other mode said first coupler means connects one of said side gears to said input shaft for rotation therewith, said second coupler means connects said casing to one of said output shafts for rotation therewith and said third coupler means connects said cross pin to the other of said output shafts for rotation therewith.

Claim 5

A transfer case assembly comprising a transfer case housing, an input shaft rotatably supported in said housing, a first output shaft rotatably supported in said housing in axial alignment with said input shaft, a differential cross and a differential casing each rotatably supported in coaxial relation to and between said input and first output shafts, and differential cross including cross pin means, a pair of pinion gears and a pair of side gears disposed in said differential casing with said pinion gears each being rotatable on said pin means and with each of said pinion gears meshing with both of said side gears, a second output shaft rotatably supported in said housing parallel to and offset from said input shaft, first drive sprocket rotatably supported in said housing coaxially of said input shaft, second drive sprocket rotatably supported on said second output shaft in a non-rotational fixed relation therewith, chain drive means directly connecting said two sprockets, first, second and third coupler means and side gear locking means slidably disposed within said housing for movement between a first and second position, shifting means for selectively moving in unison said three coupler means and said side gear locking means to either of said first and second positions, wherein said first position said first coupler means connects said cross pin to said input shaft for rotation therewith, said second coupler means connects one of said side gears to said first output shaft for rotation therewith and said third coupler means connects the other of said side gears to said first drive sprocket for rotation therewith and wherein said second position said first coupler means connects said other side gear to said input shaft for rotation therewith, said gear locking means engages and holds said one side gear in non-rotative engagement relative to said housing, said second coupler means connects said casing to said first output shaft and said third coupler means connects said cross pin to said first drive sprocket for rotation therewith.

Claim 6

A transfer case assembly comprising a transfer case housing, an input shaft rotatably supported in said housing, a first output shaft rotatably supported in said housing in axial alignment with said input shaft, a differential cross and a differential casing each rotatably supported in coaxial relation to and between said input and first output shafts, and differential cross including cross pin means, a pair of pinion gears and a pair of side gears disposed in said differential casing with said pinion gears each being rotatable on said pin means and with each of said pinion gears meshing with both of said side gears, a second output shaft rotatably supported in said housing parallel to and offset from said input shaft, first drive sprocket rotatably supported in said housing coaxially of said input shaft, second drive sprocket rotatably supported on said second output shaft in a non-rotational fixed relation therewith, chain drive means directly connecting said two sprockets, first, second and third coupler means and side gear locking means slidably disposed within said housing for movement between a first and second position, shifting means for selectively moving in unison said three coupler means and said side gear locking means to either of said first and second positions, wherein said first position said first coupler means connects said cross pin to said input shaft for rotation therewith, said second coupler means connects one of said side gears to said first output shaft for rotation therewith and said third coupler means connects the other of said side gears to said first drive sprocket for rotation therewith and wherein said second position said first coupler means connects said other side gear to said input shaft for rotation therewith, said gear locking means engages and holds said one side gear in non-rotative engagement relative to said housing, said second coupler means connects said casing to said first output shaft and said third coupler means connects said cross pin to said first drive sprocket for rotation therewith.

Claim 7

The combination of claim 4, wherein said first coupler means comprises an inner hub having a cylindrical body portion with one annular end formed with internal splines in its central bore of a size for providing sliding along the external splines of said input shaft and with its other annular end having internal splines in its central bore and wherein said third coupler means comprises an outer hub coaxially disposed about and fixed to said inner hub, said outer hub having a cylindrical body portion with one annular end extending beyond said other annular end of said inner hub which is formed with internal splines in its central bore and having external splines extending substantially along its entire length from said one annular end.

Claim 8

The combination of claim 4, wherein said second coupler means comprises a slidable member having internal axially extending splines formed in one annular end for sliding engagement with the external splines on said first output shaft and having a cylindrical portion extending coaxially about said first output shaft from said one annular end and a ring portion formed at its other end with internal splines formed in the central bore of said ring portion.

Claim 9

A transfer case assembly comprising a transfer case housing, an input shaft rotatably supported in said housing, a differential cross and a differential casing each rotatably mounted within said housing, said differential cross including cross pin means, a pair of pinion gears and a pair of side gears disposed in said differential casing with said pinion gears each being rotatably mounted on said pin means and with each of said pinion gears meshing with both of said side gears, first and second output shafts rotatably supported in said housing, first, second and third coupler means and side gear locking means slidably disposed within said housing for movement between a first and second position, shifting means for selectively moving in unison said three coupler means and said side gear locking means to either of said first and second positions, wherein said first position said first coupler means connects said cross pin to said input shaft for rotation therewith, said second coupler means connects one of said side gears to one of said output shafts for rotation therewith and said third coupler means connects the other of said side gears to the other of said output shafts for rotation therewith, and wherein said second position said first coupler means connects one of said side gears to said input shaft for rotation therewith, said gear locking means engages and holds the other of said side gears in non-rotative engagement relative to said housing, said second coupler means connects said casing to one of said output shafts for rotation therewith and said third coupler means connects said cross pin to the other of said output shafts for rotation therewith.

Claim 10

A transfer case assembly comprising a transfer case housing, an input shaft rotatably supported in said housing, a differential cross and a differential casing each rotatably mounted within said housing, said differential cross including cross pin means, a pair of pinion gears and a pair of side gears disposed in said differential casing with said pinion gears each being rotatably mounted on said pin means and with each of said pinion gears meshing with both of said side gears, first and second output shafts rotatably supported in said housing, first, second and third coupler means and side gear locking means slidably disposed within said housing for movement between a first and second position, shifting means for selectively moving in unison said three coupler means and said side gear locking means to either of said first and second positions, wherein said first position said first coupler means connects said cross pin to said input shaft for rotation therewith, said second coupler means connects one of said side gears to one of said output shafts for rotation therewith and said third coupler means connects the other of said side gears to the other of said output shafts for rotation therewith, and wherein said second position said first coupler means connects one of said side gears to said input shaft for rotation therewith, said gear locking means engages and holds the other of said side gears in non-rotative engagement relative to said housing, said second coupler means connects said casing to one of said output shafts for rotation therewith and said third coupler means connects said cross pin to the other of said output shafts for rotation therewith.

Claim 11

The combination of claim 7, wherein said first coupler means comprises an inner hub having a cylindrical body portion with one annular end formed with internal splines in its central bore of a size for providing sliding along the external splines of sAid input shaft and with its other annular end having internal splines in its central bore and wherein said third coupler means comprises an outer hub coaxially disposed about and fixed to said inner hub, said outer hub having a cylindrical body portion with one annular end extending beyond said other annular end of said inner hub which is formed with internal splines in the central bore and having external splines extending substantially along its entire length from said one annular end.

Claim 12

The combination of claim 7, wherein said second coupler means comprises a slidable member having internal axially extending splines formed in one annular end for sliding engagement with the external splines on said first output shaft and having a cylindrical portion extending coaxially about said first output shaft from said onee annular end and a ring portion formed at its other end with internal splines formed in the central bore of said ring portion.