Locking differential

Abstract

A locking differential assembly includes a differential case carrying both a differential gear set and a planetary gear set. The planetary gear set transfers torque to the differential case. In certain implementations, the differential case includes a monolithic housing that holds both the differential gear set and the planetary gear set. The monolithic housing may include an intermediate wall between the two gear sets. In certain examples, the differential case also includes an end cap mounted to the monolithic housing.

Description

Attorney Docket No. 15720.1157WOU1LOCKING DIFFERENTIALCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Indian Provisional Application No. 202411075036, filed October 4, 2024, and titled LOCKING DIFFERENTIAL, and of Indian Provisional Application No. 202411092653, filed November 27, 2024, and titled LOCKING DIFFERENTIAL, the disclosures of which are hereby incorporated herein by reference in their entirety.BACKGROUND

[0002] During normal operation of a motor vehicle, it is common that all four wheels are not turning at an identical rate of speed. Different wheel turn rates are most commonly encountered when the vehicle is making a turn, but may also be caused by braking or non- uniform road surface conditions. In order to accommodate differing wheel turning rates while continuing to direct power to two wheels, a differential is configured to allow for different wheel turn rates between the powered wheels. The differential allows the wheels to spin at different rates while transmitting torque to each wheel.

[0003] While this solution may be satisfactory in some driving conditions, it is unsatisfactory under conditions where one of the driven wheels experiences a surface having a much lower coefficient of friction than a surface engaged by the other wheel(s). Such conditions may prevent the application of torque to a wheel with more traction, thereby resulting in undesired vehicle performance. A locking mechanism may be provided to lock the differential and prevent different wheel spin rates and transmit torque uniformly between two wheels in at least some circumstances.SUMMARY

[0004] In accordance with certain aspects of the disclosure, a differential assembly includes a gear case arrangement; and an end cap arrangement configured to mount to the gear case arrangement. The gear case arrangement and the end cap arrangement cooperate to define a first interior region in which a differential gear set is disposed. The gear case arrangement defines a second interior region in which a case gear set is disposed.

[0005] In certain implementations, the gear case includes an interior wall that separates the first and second interior regions. In certain examples, the interior wall defines a passage connecting the first and second interior regions.Attorney Docket No. 15720.1157WOU1

[0006] In certain implementations, the differential gear set includes a first side gear, a second side gear, and a plurality of pinion gears. In certain examples, the differential gear set includes three pinion gears. In certain examples, the differential gear set includes a yoke member defining a plurality of cross-shafts each receiving one of the pinion gears.

[0007] In certain implementations, the end cap arrangement carries a lock arrangement that is configured to cause the differential gear set to lock the axles to the gear casing. In certain examples, the lock arrangement is electro-magnetically controlled.

[0008] In certain implementations, the case gear set includes a planetary gear set. In certain examples, a sun gear of the planetary gear set is coaxial with one of the axles of the differential assembly.

[0009] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

[0011] FIG. 1 is a schematic diagram of an example differential assembly including a differential gear set, a locking arrangement, and a case gear set.

[0012] FIG. 2 is a perspective view of an example implementation of the differential assembly of FIG. 1.

[0013] FIG. 3 is a first perspective view of the differential assembly of FIG. 2 including an end cap arrangement exploded away from a gear case arrangement for ease in viewing an interior of the gear case.

[0014] FIG. 4 is a second perspective view of the differential assembly of FIG. 3.

[0015] FIG. 5 shows an example implementation of the gear case arrangement of FIG. 3 with a differential gear set exploded outwardly for ease in viewing.

[0016] FIG. 6 is an end view of the differential assembly of FIG. 2 showing an example implementation of a case gear set including a planetary gear set.

[0017] FIG. 7 is a first perspective view of an example gear case suitable for use in the gear case arrangement of FIG. 5.Attorney Docket No. 15720.1157WOU1

[0018] FIG. 8 is a second perspective view of the gear case of FIG. 7.

[0019] FIG. 9 is a first perspective view of an axial cross-section of the gear case of FIG.

[0020] FIG. 10 is a second perspective view of an axial cross-section of the gear case of FIG. 8.

[0021] FIG. 11 is a perspective view of an example end cap arrangement carrying a lock arrangement.

[0022] FIG. 12 is another perspective view of the end cap arrangement of FIG. 11.

[0023] FIG. 13 is a first perspective view of the end cap arrangement of FIG. 11 with the components exploded from each other for ease in viewing.

[0024] FIG. 14 is a second perspective view of the exploded components of FIG. 11.

[0025] FIG. 15 is an axial cross-section of the end cap arrangement of FIG. 11.

[0026] FIG. 16 is a side elevational view of the differential assembly of FIG. 2.

[0027] FIG. 17 is an axial cross-sectional view of the differential assembly of FIG. 16.

[0028] FIG. 18 is a perspective view of an example implementation of the differential assembly of FIG. 1.

[0029] FIG. 19 is another perspective view of the differential assembly of FIG. 18.

[0030] FIG. 20 is an axial cross-sectional view of the differential assembly of FIG. 18.

[0031] FIG. 21 is an end view of the differential assembly of FIG. 18 with an example case gear set shown schematically.

[0032] FIG. 22 is a first perspective view of the differential assembly of FIG. 18 with the component exploded away from each other for ease in viewing.

[0033] FIG. 23 is a second perspective view of the differential assembly of FIG. 18 with the component exploded away from each other for ease in viewing.

[0034] FIG. 24 is a first perspective view of an example end cap suitable for use in the differential assembly of FIG. 18.

[0035] FIG. 25 is a second perspective view of the end cap of FIG. 24.

[0036] FIG. 26 is an end view of the end cap of FIG. 24.

[0037] FIG. 27 is a perspective view of an example gear case suitable for use in the differential assembly of FIG. 18.

[0038] FIG. 28 is an end view of the gear case of FIG. 27.

[0039] FIG. 29 is a first perspective view of an example lock member suitable for use in a locking arrangement of the differential assembly of FIG. 18.

[0040] FIG. 30 is a second perspective view of the lock member of FIG. 29.Attorney Docket No. 15720.1157WOU1

[0041] FIG. 31 is an end view of the lock member of FIG. 29.

[0042] FIG. 32 is a perspective view of the gear case of FIG. 27.

[0043] FIG. 33 is a side view of the gear case of FIG. 27.

[0044] FIG. 34 is an axial cross-sectional view of the gear case of FIG. 27.DETAILED DESCRIPTION

[0045] Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0046] Referring to FIG. 1, a differential assembly 100, 200 includes a differential case 102, 202 configured to rotate about an axis R. A differential gear set 104, 204 is disposed within the differential case 102, 202 between a first axle 106, 206 and a second axle 108, 208. Each axle 106, 206, 108, 208 extends out to a corresponding wheel. The differential gear set 104, 204 enables the axles 106, 206, 108, 208 to rotate independently of each other during normal operation. The differential assembly 100, 200 also includes a locking arrangement 110, 210 configured to selectively lock both of the axles 106, 206, 108, 208 to the differential case 102, 202 to rotate in unison therewith, thereby rotationally locking the axles 106, 206, 108, 208 to each other. The rotation of the differential case 102, 202 is driven by a prime mover 112 (e.g., an electrical motor, an internal combustion engine, etc.) via a case gear set 114, 214. In some examples, the case gear set 114 can be a ring gear. In other examples, the case gear set 114, 214 can be a planetary gear set.

[0047] FIGS. 2-17 show a first example implementation of the differential assembly 100 of FIG. 1. The differential case 102 extends along the rotation axis R between a first end 116 and a second end 118. The first end 116 defines a first aperture 136 and the second end 118 defines a second aperture 138. The differential case 102 includes a gear case 122 and an end cap arrangement 124 (e.g., see FIGS. 3 and 4). The end cap arrangement 124 defines the first end 116 of the differential case 102. In certain examples, the end cap arrangement 124 carries the locking arrangement 110 as will be described in more detail herein. The gear case 122 defines the second end 118 of the differential case 102.

[0048] The gear case 122 and the end cap arrangement 124 cooperate to define a first interior region 126 of the differential case 102 in which the differential gear set 104 is disposed. During assembly, the differential gear set 104 can be inserted into the gear case 122 and then the end cap arrangement 124 can be mounted to the gear case 122 to enclose the differential gear set 104. In certain examples, the end cap arrangement 124 can be fastened (e.g., bolted),Attorney Docket No. 15720.1157WOU1 welded, or otherwise secured to the gear case 122 during assembly of the differential case 102. In the example shown, the differential gear set 104 includes a yoked pinion arrangement 130, a first side gear 132, and a second side gear 134 (e.g., see FIG. 5). In certain examples, crossshafts of the yoked pinion arrangement 130 protrude into radial passages 158 extending through the gear case 122 (e.g., see FIG. 17).

[0049] The gear case 122 defines a second interior region 128 of the differential case 102 in which the case gear set 114 can be disposed. As shown in FIG. 6, an example case gear set 114 suitable for use with the differential case 102 includes a planetary gear set. In certain implementations, the case gear set 114 may include a sun gear 140 and a plurality of planet gears 142. For example, the planet gears may include first, second, and third planet gears 142 A, 142B, 142C, respectively. The sun gear 140 is configured to extend into the gear case 122 through the second aperture 138 and towards the second side gear 134. In certain examples, the sun gear 140 is coaxially mounted over the second axle 108. In certain implementations, the planet gears 142 extend radially into second interior region 128 through windows 144 defined in the gear case 122.

[0050] Referring to FIGS. 7-10, the gear case 122 extends between opposite first and second ends 146, 148, respectively. The first end 146 defines an aperture 156 leading to an interior of the gear case 122. The gear case 122 also defines an interior wall 120 disposed within the interior between the first and second ends 146, 148. The wall 120 defines a passage 125 extending between the first and second regions 126, 128. In certain examples, the wall 120 defines lubricant channels or passages 154 leading through the passage 125. The second interior region 128 of the differential case 102 is defined between the interior wall 120 and the second end 148 of the gear case 122. The second end 148 of the gear case 122 defines the second end 118 of the differential case 102.

[0051] The aperture 156 at the first end 146 of the gear case 122 leads to an interior cavity150 that extends to the interior wall 120. In certain examples, the interior cavity 150 is a stepped interior cavity. In certain implementations, the interior cavity 150 cooperates with a cavity 170 of the end cap arrangement 124 to define the first interior region 126. In certain examples, the interior cavity includes a shoulder 152 recessed into the cavity 150 from the first end 146 of the gear case 122. In certain examples, the shoulder 152 abuts an end of the end cap arrangement 124 when the end cap arrangement 124 is mounted at the first end 146 of the gear case 122. In certain examples, the radial passages 158 extend from an exterior of the gear case 122 to the interior cavity 150. In certain examples, the radial passages 158 axially extend across the shoulder 152 (e.g., see FIG. 9). For example, each radial passage 158 may define aAttorney Docket No. 15720.1157WOU1 groove 166 configured to receive part of a cross-shaft of the yoked pinion arrangement 130 (e.g., see FIGS. 9 and 10).

[0052] In certain implementations, the interior wall 120 has a triangular shape (e.g., see FIG. 8). In certain examples, the passage 125 extends through a center of the triangular shape. In certain examples, sides 160 of the wall 120 are recessed inwardly from the windows 144 of the gear case 122. In certain examples, the sides 160 of the wall 120 are recessed sufficiently radially inwardly to accommodate axles of planet gears 142 disposed within the second interior region 128. For example, the sides 160 are recessed sufficient so that insertion axes IA of apertures 162 defined in the second end 148 of the gear case 122 do not intersect the interior wall 120 (e.g., see FIGS. 9 and 10). In certain examples, the sides 160 define radial windows 164 leading to the interior cavity 150 (e.g., see FIG. 8). In an example, lubricant can splash from the gear case windows 144, through the radial windows 164, to the differential gear set 104 within the first interior region 126.

[0053] FIGS. 11-14 show an example end cap arrangement 124. The end cap arrangement 124 defines a cavity 170 that cooperates with the cavity 150 of the gear case 122 to define the first interior region 126 of the differential case 102. The cavity 170 is accessible through an opening 172 at one axial end of the end cap arrangement 124. In certain examples, a circumference of the opening 172 is recessed radially inwardly from an outer circumference of the end cap arrangement 124. Recessing the opening 172 provides support for bolts B or other fasteners for attaching the end cap arrangement 124 to the gear case 122. In certain implementations, the end cap arrangement 124 defines a first abutment surface 174 facing the gear case 122 when the end cap arrangement 124 is mounted to the gear case 122. A lip 176 extends axially outwardly from the first abutment surface 174 to a second abutment surface 178. The second abutment surface 178 bounds the opening 172 through which the cavity 170 is accessible. The lip 176 defines grooves 180 in the second abutment surface 178.

[0054] When the end cap arrangement 124 is mounted to the gear case 122, the lip 176 of the end cap arrangement 124 extends into the aperture 156 at the first end 146 of the gear case 122. In certain examples, the second abutment surface 178 of the end cap arrangement 124 abuts against the shoulder 152 within the cavity 150 while the first abutment surface 174 abuts against the first end 146 of the gear case 122. In certain examples, the grooves 180 in the lip 176 of the end cap arrangement 124 cooperate with the grooves 166 in the gear case 122 to accommodate the cross-shafts of the yoked pinion arrangement 130. In some implementations, the end cap arrangement 124 can be pre-assembled together and then mounted to the gear caseAttorney Docket No. 15720.1157WOU1122 as a unit. In other implementations, components of the end cap arrangement 124 can be separately attached.

[0055] As shown in FIGS. 13 and 14, the end cap arrangement 124 includes a first housing 182 and a second housing 184 that cooperate to hold the locking arrangement 110. The locking arrangement 110 includes a stator 190 holding an electro-magnet C (e.g., coil), an armature 192 configured to be selectively moved by the stator 190, a lock member 186 (e.g., a lock plate, a lock collar, etc.), and a plurality of pins 194 extending through the first housing 182 between the armature 192 and the lock member 186. The lock member 186 carries teeth 195 (e.g., dog teeth) configured to selectively mesh with lock teeth 135 (e.g., see FIG. 5) of the first side gear 132.

[0056] Both the armature 192 and the lock member 186 are configured to move (e.g., slide) along the rotation axis R relative to the first and second housings 182, 184 between a locking position and a releasing position. A biasing member 188 biases the lock member 186 towards the releasing position. In certain examples, the second housing 184 includes a support surface 185 (e.g., a protruding ring) against which the biasing member 188 is supported. The pins 194 transfer movement of the lock member 186 towards the releasing position into movement of the armature 192 towards the releasing position. Activating the electro-magnet at the stator 190, however, counters the bias to move the armature 192 towards the locking position. The pins 194 transfer movement of the armature 192 towards the locking position into movement of the lock member 186 towards the locking position.

[0057] The teeth 195 of the lock member 186 mesh with the teeth 135 of the first side gear 132 of the differential gear set 104 when the lock member 186 is disposed in the locking position. Accordingly, the lock member 186 and the first side gear 132 rotate in unison. The lock member 186 also includes torque transfer members 196 (e.g., ears or radial lugs) that fit into grooves 198 defined by the first housing 182. Interaction between the torque transfer members 196 and the grooves 198 causes the lock member 186 to rotate in unison with the first housing 182. Accordingly, the locking arrangement 110 causes the first side gear 132 to rotate in unison with the first housing 182 (and hence the differential case 102) when the armature 192 is disposed in the locking position.

[0058] FIGS. 18-34 show another example implementation of the differential assembly 200 of FIG. 1. The differential case 202 extends along the rotation axis R between a first end 216 and a second end 218. The first end 216 defines a first aperture 236 and the second end 218 defines a second aperture 238. The differential case 202 includes a gear case 222 and an end cap arrangement 224 (e.g., see FIGS. 22 and 23). The end cap arrangement 224 includesAttorney Docket No. 15720.1157WOU1 an end cap 223 that defines the first end 216 of the differential case 202. In certain examples, the locking arrangement 210 is carried by the end cap 223 as will be described in more detail herein. The gear case 222 defines the second end 218 of the differential case 202.

[0059] The gear case 222 and the end cap arrangement 224 cooperate to define a first interior region 226 of the differential case 202 in which the differential gear set 204 is disposed. For example, the end cap arrangement 224 defines a cavity 270 that cooperates with a cavity 250 of the gear case 222 to define the first interior region 226. During assembly, the differential gear set 204 can be inserted into the gear case 222 and then the end cap arrangement 224 can be mounted to the gear case 222 to enclose the differential gear set 204. In certain examples, the end cap 223 can be fastened (e.g., bolted), welded, or otherwise secured to the gear case 222 during assembly of the differential case 202.

[0060] In the example shown, the differential gear set 204 includes a yoked pinion arrangement 230, a first side gear 232, and a second side gear 234 (e.g., see FIG. 20). In certain examples, cross-shafts 257 of the yoked pinion arrangement 230 protrude into radial passages 258 extending through the differential case 202 (e.g., see FIG. 20) between the interior region 226 and exterior of the differential case 202. In certain implementations, the gear case 222 and the end cap 223 cooperate to define the radial passages 258. For example, the end cap 223 may define a plurality of first grooves 280 and the gear case 222 may define a plurality of second grooves 282 that align with the first grooves 280 when the end cap 223 is mounted to the gear case 222. When the differential case 202 is assembled, the yoked pinion arrangement 230 is mounted at the interior region 226 with the pinions extending along the second grooves 282. The end cap 223 is mounted to the gear case 222 so that the first grooves 280 cover the pinions and cooperate with the second grooves 282 to define the radial passages 258.

[0061] In certain examples, one of the gear case 222 and the end cap 223 defines a peripheral groove and the other includes a peripheral lip that fits with the groove. In the example shown, the end cap 223 defines the peripheral groove 284 (e.g., see FIG. 25) and the gear case 222 defines the peripheral lip 285 (e.g., see FIG. 27). When the differential case 202 is assembled, the peripheral lip 285 of the gear case 222 seats in the peripheral groove 284 of the end cap 223 (e.g., see FIG. 20).

[0062] Referring to FIGS. 20, 21, and 32-34, the gear case 222 defines a second interior region 228 of the differential case 202 in which the case gear set 214 can be disposed. As shown in FIG. 21, an example case gear set 214 suitable for use with the differential case 202 includes a planetary gear set. In certain implementations, the case gear set 214 may include aAttorney Docket No. 15720.1157WOU1 sun gear 240 and a plurality of planet gears 242. For example, the planet gears 242 may include first, second, and third planet gears 242A, 242B, 242C, respectively.

[0063] The sun gear 240 is configured to extend into the gear case 222 through the second aperture 238 and towards the second side gear 234. In certain examples, the sun gear 240 is coaxially mounted over the second axle 208. In certain implementations, the planet gears 242 extend radially into the second interior region 228 through windows 244 defined in the gear case 222. In certain examples, the gear case 222 defines one or more mounting apertures 239, 262 through which portions of the planet gears 242 extend to support the planet gears 242 at the differential case 202. In certain examples, the end cap 223 defines pockets 299 or apertures aligned with the mounting apertures 239 to receive and / or support ends of the planet gears 242 (e.g., see FIG. 25). In certain examples, lubricant grooves extend radially outwardly from the mounting apertures 239 to assist in directing lubricant to the planet gears 242.

[0064] Referring to FIGS. 20, 22, and 23, the locking arrangement 210 includes a stator 290 and an armature 292 disposed external of the end cap 223. The stator 290 holds an electromagnet C (e.g., coil). The armature 292 is configured to be selectively moved by the stator 290. The locking arrangement 210 also includes a lock member 286 (e.g., a lock plate, a lock collar, etc.) disposed within the differential case 202 and a plurality of pins 294 extending through the end cap 223 between the armature 292 and the lock member 286 (e.g., see FIG. 20). The lock member 286 carries teeth 295 (e.g., dog teeth) configured to selectively mesh with lock teeth 235 of the first side gear 232.

[0065] Both the armature 292 and the lock member 286 are configured to move (e.g., slide) along the rotation axis R relative to the end cap 223 between a locking position and a releasing position. A biasing member 288 biases the lock member 286 towards the releasing position. The pins 294 transfer movement of the lock member 286 towards the releasing position into movement of the armature 292 towards the releasing position. Activating the electro-magnet at the stator 290, however, counters the bias to move the armature 292 towards the locking position. The pins 294 transfer movement of the armature 292 towards the locking position into movement of the lock member 286 towards the locking position.

[0066] The teeth 295 of the lock member 286 mesh with the teeth 235 of the first side gear 232 of the differential gear set 204 when the lock member 286 is disposed in the locking position. Accordingly, the lock member 286 and the first side gear 232 rotate in unison. The lock member 286 also includes torque transfer members 296 (e.g., ears or radial lugs) that fit into grooves 298 defined by the end cap 223. Interaction between the torque transfer members 296 and the grooves 298 causes the lock member 286 to rotate in unison with the end cap 223.Attorney Docket No. 15720.1157WOU1Accordingly, the locking arrangement 210 causes the first side gear 232 to rotate in unison with the end cap 223 (and hence the differential case 202) when the armature 292 is disposed in the locking position.

[0067] In some implementations, the torque transfer members 296 are evenly circumferentially spaced about the lock member 286. In other implementations, however, the torque transfer members 296 can be clustered in groups 297 that are evenly circumferentially spaced about the lock member 286. In the example shown, the groups 297 include pairs of torque transfer members 296. Each torque transfer member 296 within a group 297 is separated by a first gap G1 and each group 297 is separated by a second gap G2 that is larger than the first gap Gl. In certain examples, the second gap G2 is at least twice as long as the first gap Gl. The gaps G2 between groups 297 of torque transfer members 296 accommodate the pinions of the yoked pinion arrangement 230. For example, the grooves 298 defined in the end cap 223 may be spaced away from the grooves 280 holding the pinion cross-shafts (e.g., see FIG. 26). Accordingly, the grooves 298 need not cut through material otherwise supporting the pinions of the yoked pinion arrangement 230.

[0068] The lock member 286 has a first axial end 301 facing towards the armature 292 and a second axial end 303 facing towards the yoked pinion arrangement 230. In certain examples, the second axial end 303 carries the teeth 295. In certain implementations, the lock member 286 is a ring defining an inner passage 305. The second axial end 303 of the lock member 286 defines a support surface 307 radially extending between the inner passage 305 and the teeth 295. In certain examples, one or more lubrication slots 309 cut into the support surface 307 from the inner passage 305.

[0069] As shown in FIG. 20, the lock member 286 mounts over the first side gear 232 so that a portion of the side gear 232 extends through the inner passage 305. In certain examples, the biasing member 288 also seats on the portion of the first side gear 232. The biasing member 288 of the locking arrangement 210 engages the support surface 307 of the lock member 286. In certain examples, the biasing member 288 is captured between the support surface 307 of the lock member 286 and a groove defined in the first side gear 232.

[0070] Referring to FIGS. 27, 28, and 32-34, the gear case 222 extends between opposite first and second ends 246, 248, respectively. The first end 246 defines an aperture 256 leading to an interior of the gear case 222. The gear case 222 also defines an interior wall 220 disposed within the interior between the first and second ends 246, 248. The second interior region 228 of the differential case 202 is defined between the interior wall 220 and the second end 248 ofAttorney Docket No. 15720.1157WOU1 the gear case 222. The second end 248 of the gear case 222 defines the second end 218 of the differential case 202.

[0071] In certain implementations, the interior wall 220 has a circular shape. In certain examples, a periphery 260 of the wall 220 is recessed inwardly from the windows 244 of the gear case 222. In certain examples, the periphery 260 of the wall 220 is recessed sufficiently radially inwardly to accommodate axles PG of planet gears 242 disposed within the second interior region 228 (e.g., see FIG. 19). For example, the periphery 260 is recessed sufficient so that insertion axes PG of apertures 262 defined in the second end 248 of the gear case 222 do not intersect the interior wall 220 (e.g., see FIG. 19). In an example, lubricant can splash from the gear case windows 244 to the differential gear set 204 within the first interior region 226.

[0072] The wall 220 defines a passage 225 extending between the first and second regions 226, 228. In certain examples, the wall 220 defines lubricant grooves 254 leading to the passage 225. In certain examples, lubricant channels 255 extend through the passage 225 between the first and second regions 226, 228. In certain examples, the lubricant channels 255 have a helix or double-helix configuration. In other examples, the lubricant channels 255 may extend linearly.

[0073] In certain implementations, the gear case 222 defines radially-extending lubricant channels 252 to assist in distributing lubricant within the differential case 202. Lubricant sits in a sump in which a portion of the differential case 202 seats. As shown in FIG. 34, the lubricant has a level S that sits below the passage 225 through the wall 220. In certain examples, the lubricant level S is below the periphery of the wall 220. As the differential case 202 rotates, however, a peripheral end of each lubricant channel 252 periodically enters the sump and scoops up some the lubricant into the channel 252. As the differential case 202 continues to rotate, the lubricant flows radially inwardly along the channels 252 towards the differential gear set 204. In certain examples, the lubricant channels 252 are disposed in the first interior region 226 of the gear case 222.

[0074] In certain implementations, the end cap 223 also defines lubricant channels and apertures to assist in directing lubricant to the differential gear set 204. In certain implementations, a helical or double-helical lubricant channel 251 extends inwardly from the aperture 236 towards the interior cavity 270. Notches 251a, 251b may assist in guiding lubricant into and out of the lubricant channel 251. In certain implementations, the end cap 223 also may define one or more radial apertures 253 leading from an exterior of the end cap 223 into the interior cavity 270. In certain examples, a nozzle connected to a lubricant sourceAttorney Docket No. 15720.1157WOU1 can be aimed at the aperture 236 and / or the aperture 253 to spray lubricant into the end cap 223.

[0075] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.

Claims

Attorney Docket No. 15720.1157WOU1What is claimed is:

1. A locking differential assembly comprising: a differential case extending along a rotation axis between a first end and a second end, the differential case including an intermediate wall disposed at an intermediate location along the rotation axis, the differential case defining a first interior region extending from the first end to the intermediate wall and the differential case defining a second interior region extending from the intermediate wall to the second end, the intermediate wall defining a passage between the first and second interior regions; and a differential gear set including a first side gear, a second side gear, and a yoked pinion assembly, the first side gear and the yoked pinion assembly disposed at the first interior region of the differential case, the second side gear having a first part disposed within the first interior region and a second part extending through the passage of the intermediate wall.

2. The locking differential assembly of claim 1, wherein the first end of the differential case defines a first aperture leading to the first interior region, and the second end of the differential case defines a second aperture leading to the second interior region.

3. The locking differential assembly of claim 2, further comprising an end cap assembly configured to mount to the first end of the differential case to cover the first aperture.

4. The locking differential assembly of claim 3, wherein the end cap assembly includes a locking arrangement by which the differential gear set can be selectively rotationally locked to the differential case.

5. The locking differential assembly of claim 4, wherein the end cap assembly includes a first housing and a second housing, and wherein the first and second housings of the end cap assembly hold a lock member and a biasing member of the locking arrangement therebetween.

6. The locking differential assembly of claim 4, wherein the end cap assembly includes a single-piece housing to which the locking arrangement mounts, the single-piece housing mounting to the differential case.Attorney Docket No. 15720.1157WOU17. The locking differential assembly of claim 3, wherein the differential case cooperates with the end cap assembly to define radial passages in which pinions of the yoked pinion assembly are disposed.

8. The locking differential assembly of claim 1, wherein the differential case fully defines radial passages in which pinions of the yoked pinion assembly are disposed.

9. The locking differential assembly of claim 2, further comprising a planetary gear set including a sun gear shaft and a plurality of planet gears, the sun gear shaft extending through the second aperture.

10. The locking differential assembly of claim 9, wherein the differential case defines a plurality of windows extending radially between the second interior region and an exterior of the differential case, and wherein each of the planet gears is disposed at a respective one of the windows so that the planet gears extend partially into the second interior region.

11. The locking differential assembly of claim 10, wherein sides of the intermediate wall are recessed inwardly from the windows of the differential case, the sides defining radial windows leading to the first interior region to enable lubricant splash access to the differential gear set.

12. The locking differential assembly of claim 1, wherein the intermediate wall defines lubricant channels leading through the passage.

13. A locking differential assembly comprising: a differential case extending along an axis between opposite first and second ends, the differential case defining a first interior region at the first end of the differential case and defining a second interior region at the second end of the differential case, the first and second interior regions being connected by a passage; a differential gear set disposed at least partially within the first interior region; and a planetary gear set including a sun gear disposed at least partially within the second interior region, the sun gear being coaxial with the passage.Attorney Docket No. 15720.1157WOU114. The locking differential assembly of claim 13, wherein a portion of the differential gear set extends into the passage.

15. The locking differential assembly of claim 13, wherein the differential case defines a plurality of windows, the windows axially spanning at least a portion of the first interior region and at least a portion of the second interior region.

16. The locking differential assembly of claim 13, wherein the differential case defines radial passages for pinions of the differential gear set.

17. The locking differential assembly of claim 13, wherein the differential case cooperates with an end cap to define radial passages for pinions of the differential gear set.

18. A locking differential assembly comprising: a gear case extending along a rotation axis between a first end and a second end, the gear case including an intermediate wall disposed at an intermediate location along the rotation axis, the gear case defining a first interior region extending from the first end to the intermediate wall and the gear case defining a second interior region extending from the intermediate wall to the second end, the intermediate wall defining a passage between the first and second interior regions; an end cap configured to mount to the gear case, the end cap defining a cavity configured to cooperate with the first interior region to form a pocket; a differential gear set disposed within the pocket, the differential gear set including a first side gear, a second side gear, and a yoked pinion assembly; and a lock arrangement including an armature disposed at an exterior of the end cap, a locking plate disposed within the pocket, pins extending through the end cap to connect the armature and the locking plate, and a biasing member captured between the locking plate and the first side gear.

19. The locking differential assembly of claim 18, wherein the gear case and the end cap cooperate to define radial passages in which cross-shafts of the yoked pinion assembly are disposed.Attorney Docket No. 15720.1157WOU120. The locking differential assembly of claim 18, wherein the intermediate wall has a circular transverse cross-section.

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