DIFFERENTIAL GEAR CASE

摘要

An integral differential case (10) for a cross axis, compound planetary gear differential that includes end portions (10a, 10b) each defining an axle receiving bore (14, 28) and trunnions (12, 26) by which the case is rotatably supported within a housing, and, an intermediate portion (10c) located between the end portions. The intermediate portion includes a through passage (50) defining transfer gear windows (52, 54) at each end. Each transfer gear window is defined at least partially by spaced apart window wall sections (56), disposed in planes that extend on either side of an axis of rotation (20) for the differential case. Intermediate wall sections (58) are disposed along the passage intermediate the transfer gear windows (52, 59) and are disposed in parallel planes that intersect the axis of rotation at substantially 90. The passage is finish formed by a broaching process in which a broaching tool (80) concurrently machines the intermeidate wall sections and window wall sections in a single broaching cycle. The broached window wall sections and broached intermediate wall sections provide locating and reaction surfaces for transfer gears (60) mounted within the windows and axle drive gears (62) mounted inside the differential.