Differential spider with retaining caps for retaining bevel pinions in a differential

Claim 2

A differential assembly for a vehicle comprising: a differential frame having a central hub with a plurality of arms extending radially outwardly from a proximal end to a distal end from the central hub; a pinion gear received upon each of the plurality of arms, each said pinion gear being rotatable about the arm on which it is received; and a retaining cap removably secured to the distal end of each of the plurality of arms such that the pinion gear rotatably received on the arm is held in place between the central hub and the retaining cap, each said retaining cap supported only by the differential frame and having a free outer peripheral surface and a free axial end surface.

Claim 3

The differential assembly of claim 1 wherein a portion of each said arm near the distal end thereof has male threading formed thereon and a central aperture in each of the retaining caps has complementary female threading formed therein to removably secure the retaining cap to the arm.

Claim 4

The differential assembly of claim 2 wherein a thread locking compound is interposed between the male and female threading prior to mating thereof to secure the retaining cap to the arm.

Claim 5

The differential assembly of claim 1 wherein each said pinion gear has a generally flat axial inner surface in facial engagement with a generally flat shoulder formed at the proximal end of the arm at the central hub.

Claim 6

The differential assembly of claim 4 wherein each said pinion gear further has a convex spherical axial outer surface in facial engagement with a complementary concave spherical inner surface formed in the retaining cap.

Claim 7

The differential assembly of claim 2 wherein the retaining cap has a head portion adapted for use of a wrench in threadingly securing the retaining cap to the arm.

Claim 8

The differential assembly of claim 6 wherein the head portion has a hexagonal cross section.

Claim 9

The differential assembly of claim 7 wherein the retaining cap further has a flange portion adjacent to the head portion, the flange portion having a larger diameter than the head portion.

Claim 10

The differential assembly of claim 8 wherein the flange portion further comprises a concave spherical inner surface formed therein.

Claim 11

The differential assembly of claim 1 wherein the differential frame has four said arms.

Claim 12

A differential system, comprising: an input axle transmitting rotation, the input axle including a first side gear slidingly secured to the input axle; a differential frame having a central hub and a plurality of arms extending radially outwardly from a proximal end to a distal end from the central hub, the central hub being fixed to the input axle to directly rotate the differential frame; a pinion gear received upon each of the plurality of arms to rotate about an axis of the arm; an output axle including a second side gear fixed to the output axle, the first side gear and the second side gear each meshing with the pinion gears to transmit rotation from the input axle to the output axle; and a retaining cap removably secured to the distal end of each of the plurality of arms such that the pinion gear rotatably received on the arm is held in place between the central hub and the retaining cap, each said retaining cap supported only by the differential frame and having a free outer peripheral surface and a free axial end surface.

Claim 13

A differential system, comprising: an input axle transmitting rotation, the input axle including a first side gear slidingly secured to the input axle; a differential frame having a central hub and a plurality of arms extending radially outwardly from a proximal end to a distal end from the central hub, the central hub being fixed to the input axle to directly rotate the differential frame; a pinion gear received upon each of the plurality of arms to rotate about an axis of the arm; an output axle including a second side gear fixed to the output axle, the first side gear and the second side gear each meshing with the pinion gears to transmit rotation from the input axle to the output axle; and a retaining cap removably secured to the distal end of each of the plurality of arms such that the pinion gear rotatably received on the arm is held in place between the central hub and the retaining cap, each said retaining cap supported only by the differential frame and having a free outer peripheral surface and a free axial end surface.

Claim 14

The differential system of claim 11 wherein the retaining caps have no contact on the free outer peripheral surface or the free axial end surface with any structure of the differential system.

Claim 15

The differential system of claim 11 wherein a portion of each said arm near the distal end thereof has male threading formed thereon and a central aperture in each of the retaining caps has complementary female threading formed therein to removably secure the retaining cap to the arm.

Claim 16

The differential system of claim 13 wherein a thread locking compound is interposed between the male and female threading prior to mating thereof to secure the retaining cap to the arm.

Claim 17

The differential system of claim 11 wherein each said pinion gear has a generally flat axial inner surface in facial engagement with a generally flat shoulder formed at the proximal end of the arm at the central hub.

Claim 18

The differential system of claim 15 wherein each said pinion gear further has a convex spherical axial outer surface in facial engagement with a complementary concave spherical inner surface formed in the retaining cap.

Claim 19

The differential system of claim 16 wherein the retaining cap has a head portion adapted for use of a wrench in threadingly securing the retaining cap to the arm and a flange portion adjacent to the head portion, the flange portion having a larger diameter than the head portion.

Claim 20

The differential system of claim 17 wherein the head portion has a hexagonal cross section and the flange portion has a circular cross section.

Claim 21

The differential system of claim 18 wherein the concave spherical inner surface is formed in the flange portion of the retaining cap.