Drive axle and method of assembling same

Claim 2

In an axle assembly, the combination comprising: a differential cage, a pair of side gears disposed in said cage, each side gear having a splined opening, a pinion shaft mounted in said cage, a pair of pinion gears rotatably journaled on said pinion shaft and meshing with said side gears, a ring gear fastened to said cage and disposed to at least partially overlie said pinion shaft so that said pinion shaft cannot be removed from said cage after said ring gear is fastened to said cage, a splined axle shaft having a groove adjacent one end, said axle shaft being disposed to extend through and engage the splined opening in one of said side gears so that said one end is adjacent said pinion shaft, a plurality of separate and independent retainer ring segments disposed in said groove and engaging the adjacent side gear, and means resiliently holding said segments in said groove.

Claim 3

The combination as set forth in claim 1 wherein said holding means includes a spring encircling said segments.

Claim 4

The combinations as set forth in claim 1 wherein said holding means includes a snap ring encircling said segments.

Claim 5

The combination as set forth in claim 2 wherein said holding means includes a snap ring encircling said segments.

Claim 6

The combination as set forth in claim 1 wherein each retainer ring segment includes a first groove and a second groove, and said holding means includes a spring disposed in said first grooves and encircling said segments and a snap ring disposed in said second grooves and encircling said segments.

Claim 7

The combination as set forth in claim 5 wherein said retainer ring segments comprise means for engaging said side gear when said retainer ring segments are positioned in said axle shaft groove to prevent said axle shaft from being removed from said axle assembly.

Claim 8

The combination as set forth in claim 6 wherein said expandable ring has an inside diameter smaller than the inside diameter of said axle shaft groove.

Claim 9

The combination as set forth in claim 7 wherein each of said retainer ring segments includes a generally radially extending face adapted for engagement with a radial face of a next adjacent retainer ring segment when said expandable ring is in a collapsed condition, whereby said expandable ring is held in an annular shape prior to assembly by said spring encircling said segments.

Claim 10

The combination as defined in claim 8 wherein a radially inward portion of each of said retainer ring segments defines a first chamfer and wherein a radially outward portion of the axially inward end of said axle shaft defines a second chamfer for engaging said first chamfers during assembly, whereby said second chamfer cams said retainer ring segments radially outwardly during assembly to allow said retainer ring segments to engage said axle shaft groove.

Claim 11

The combination as set forth in claim 9 wherein each of said plurality of retainer ring segments are identical.

Claim 12

An axle assembly comprising: an axle housing having an enlarged portion and a pair of arms, a differential disposed in the enlarged portion of said housing, said differential including: a differential cage, a pair of side gears disposed in said cage, each side gear having a splined opening, a pinion shaft mounted in said cage, a pair of pinion gears rotatably journaled on said pinion shaft and meshing with said side gears, and a ring gear fastened to said cage and disposed to at least partially overlie said pinion shaft so that said pinion shaft cannot be removed from said cage after said ring gear is fastened to said cage, a pair of splined axle shafts, each axle shaft having a groove adjacent one end and each axle shaft being disposed to extend through and engage the splined opening in separate ones of said side gears so that said one end is adjacent said pinion shaft, the other end of each axle shaft being rotatably journaled in separate ones of said arms, and a pair of retainer ring assemblies, each assembly being disposed in separate ones of said grooves and engaging the adjacent side gear to prevent withdrawal of said axle shafts from the splined openings in said side gears, each assembly including a plurality of separate and independent retainer ring segments and means resiliently holding said segments in one of said grooves.

Claim 13

An axle assembly comprising: an axle housing having an enlarged portion and a pair of arms, a differential disposed in the enlarged portion of said housing, said differential including: a differential cage, a pair of side gears disposed in said cage, each side gear having a splined opening, a pinion shaft mounted in said cage, a pair of pinion gears rotatably journaled on said pinion shaft and meshing with said side gears, and a ring gear fastened to said cage and disposed to at least partially overlie said pinion shaft so that said pinion shaft cannot be removed from said cage after said ring gear is fastened to said cage, a pair of splined axle shafts, each axle shaft having a groove adjacent one end and each axle shaft being disposed to extend through and engage the splined opening in separate ones of said side gears so that said one end is adjacent said pinion shaft, the other end of each axle shaft being rotatably journaled in separate ones of said arms, and a pair of retainer ring assemblies, each assembly being disposed in separate ones of said grooves and engaging the adjacent side gear to prevent withdrawal of said axle shafts from the splined openings in said side gears, each assembly including a plurality of separate and independent retainer ring segments and means resiliently holding said segments in one of said grooves.

Claim 14

The axle assembly as set forth in claim 11 wherein each holding means includes first and second grooves in the retainer ring segments of each retainer ring assembly, a spring engaging said first grooves and encircling said segments and a snap ring engaging said second grooves and encircling said segments.