Method for controlling axle shaft endplay

• US 6,618,924 B1
• Filed: 05/22/2001
• Issued: 09/16/2003
• Est. Priority Date: 05/22/2001
• Status: Expired due to Fees

• Current Assignee: Dana Automotive Systems Group, LLC (Dana, Inc.)
• Original Assignee: Torque-Traction Technologies Incorporated (Dana, Inc.)
• Inventors: Irwin, Earl J.
• Primary Examiner(s): Hong, John C.
• Application Number:
  US09/861,654
• Time in Patent Office: 847 Days
• Field of Search: 294/070.5, 294/070.1, 294/08, 294/34, 292/38, 292/815, 475/230, 475/331, 475/231, 475/242, 475/246, 411/222, 411/321
• US Class Current: 29/407.05
• CPC Class Codes: F16H 2048/082 characterised by the arrangement of output shafts
• CPC Class Codes: F16H 2048/387 Shields or washers
• CPC Class Codes: F16H 2048/423 characterised by bearing arrangement
• CPC Class Codes: F16H 2057/0221 Axial adjustment
• CPC Class Codes: F16H 2057/0227 Assembly method measuring first tolerances or position and selecting mating parts accordingly, e.g. special sized shims for transmission bearings
• CPC Class Codes: F16H 2057/125 Adjustment of backlash during mounting or assembly of gearing
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: F16H 57/037 Gearboxes for accommodating differential gearings rotating cases for differential gearings F16H48/40
• CPC Class Codes: Y10T 29/49764 with testing or indicating
• CPC Class Codes: Y10T 29/49771 Quantitative measuring or gauging
• CPC Class Codes: Y10T 29/4984 Retaining clearance for motion between assembled parts

Abstract

A method for controlling an axle shaft endplay in a vehicle is disclosed. The desired axle shaft endplay is determined by a manufacturer based on the specific operating conditions of a differential assembly. In accordance with the endplay controlling method of the present invention, first the differential is partially assembled by mounting side gears and a set of differential pinion mate gears in a differential case. Then, the manufacturer determines a thickness of a shim ring disposed between an axle shaft retainer ring and the differential side gear, which would provide the desired endplay. The appropriate shim ring is selected from an endplay controlling kit comprising a plurality of the shim rings of assorted thickness. Next, axle shafts are inserted into the differential case through the side gears, and the selected shim ring is mounted to the axle shaft. Finally, the retainer ring is secured to the axle shaft.

Claims

1. A method for controlling an axle shaft endplay in a differential assembly, said differential assembly comprising an axle shaft non-rotatably engaging a differential side gear and having an annular groove located adjacent to a terminal shoulder provided at an inboard end of said shaft, a retainer ring disposed in said groove for limiting an axial displacement of said axle shaft in an outboard direction and a shim ring positioned on said inboard end of said axle shaft between said retainer ring and said side gear, said method comprising the steps of:

(a) assembling said side gear and a differential pinion mate gears in continuous meshing engagement with said side gear;

(b) determining a desired axle shaft endplay δ

_P;

(c) determining a thickness W_S of said shim ring that would provide said desired axle shaft endplay;

(d) selecting said shim ring having the thickness W_S as determined in the preceding step, for selectively controlling said endplay;

(e) inserting said axle shaft through said side gear from said outboard direction toward an inboard direction;

(f) inserting said selected shim ring over said axle shaft from said inboard end thereof;

(g) mounting said retainer ring in said groove in said inboard end of said axle shaft; and

(h) pulling said axle shaft outboard to sandwich said shim ring between said side gear and said retainer ring.

2. The method for controlling an axle shaft endplay in a differential assembly as defined in claim 1, wherein said step (c) includes the steps of:

measuring a distance D from a pinion shaft to an end surface of said side gear;

measuring a thickness W_TS of said terminal shoulder of said axle shaft;

measuring a thickness W_R of said retainer ring;

determining a thickness W_S of said shim ring that would provide said predetermined shaft endplay, wherein the thickness of said shim ring is determined in accordance with the following equation;

3. The method for controlling an axle shaft endplay in a differential assembly as defined in claim 1, wherein said retainer ring is a C-ring.

4. The method for controlling an axle shaft endplay in a differential assembly as defined in claim 1, wherein said shim ring is selected from an endplay controlling kit including a plurality of shim rings of assorted thickness.

5. The method for controlling an axle shaft endplay in a differential assembly as defined in claim 4, wherein the thickest shim ring in said endplay controlling kit provides a zero endplay.

6. A method for controlling an axle shaft endplay in a differential assembly, said differential assembly comprising an axle shaft adapted to non-rotatably engage a differential side gear and having an annular groove located adjacent to a terminal shoulder provided at an inboard end of said shaft, a retainer ring disposed in said groove for limiting an axial displacement of said axle shaft in an outboard direction and a shim ring positioned on said inboard end of said axle shaft between said retainer ring and said side gear, said method comprising the steps of:

(a) assembling said side gear and differential pinion mate gears in continuous meshing engagement with said side gear;

(b) determining a desired axle shaft endplay δ

_P;

(c) measuring a distance D from a pinion shaft to an end surface of said side gear;

(d) measuring a thickness W_TS of said terminal shoulder of said axle shaft;

(e) measuring a thickness W_R of said retainer ring;

(f) determining a thickness W_S of said shim ring that would provide said predetermined shaft endplay, wherein the thickness of said shim ring is determined in accordance with the following equation;

7. The method for controlling an axle shaft endplay in a differential assembly as defined in claim 6, wherein a thickest retainer ring in said endplay controlling kit provides a zero endplay.