Four pinion mate differential gear assembly having a one-piece differential case

Claim 1

A four pinion mate differential gear assembly for transmitting torque from an input shaft to a pair of side gears respectively coupled to rotate with a pair of output shafts about an output axis, said differential gear assembly comprising: a differential case having a gear chamber formed therein, said differential case supported for rotation about said output axis; a cross pin having a medial cross bore formed therethrough, said cross pin having first and second ends connected to said differential case such that said cross pin extends through said gear chamber and intersects said output axis; first and second pinion mates respectively rotatably supported in a diametrically opposed relationship on said first and second ends of said cross pin within said gear chamber, each of said first and second pinion mates provided in meshing engagement with said pair of side gears; first and second hollow pinion support sleeves seated on opposite sides of said cross pin in alignment with said medial cross bore, said first and second pinion support sleeves respectively rotatably supporting third and fourth pinion mates in diametrically opposed relationship such that said third and fourth pinion mates are in meshing engagement with said pair of side gears; first and second retainer plates, each having an aperture formed therein and respectively engaged with said first and second pinion support sleeves to retain said third and fourth pinion mates on said sleeves, said first and second retainer plates being substantially frusto-conical in configuration and extending outwardly beyond said third and fourth pinion mates, respectively; and a cross bolt extending through said medial cross bore, said first and second hollow pinion support sleeves, and said apertures formed in said first and second retainer plates to secure said third and fourth pinion mates in meshing engagement with said pair of side gears.