Patent Publication Number: US-10328796-B1

Title: Transmission to transfer case adpator kit

Description:
OTHER RELATED APPLICATIONS 
     The present application is a continuation-in-part of pending U.S. patent application Ser. No. 14/816,472, filed on Aug. 3, 2015, which is hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to truck adaptor kits, and more particularly, to two-wheel to four-wheel transmission to transfer case adaptor kits. 
     2. Description of the Related Art 
     Applicant is not aware of any prior art two-wheel to four-wheel conversion transmission to transfer case adaptor kits that suggest the novel features of the present invention. 
     SUMMARY OF THE INVENTION 
     The present invention is a vehicle two-wheel to four-wheel conversion transmission to transfer case adaptor kit to convert a two-wheel drive production truck to four-wheel drive enabling a drivetrain that allows all four wheels of the truck to receive torque from an engine of the truck, whereby the truck has a transmission system and is retrofitted with a front axle adaptor kit, and a transfer case parking brake system adaptor kit and support mount. 
     More specifically, the present invention is a transmission to transfer case adaptor kit, comprising a transfer case, a connector, a spacer assembly, and automatic or manual transmission mounting means to convert a two-wheel drive production truck to four-wheel drive enabling a drivetrain that allows all four wheels of the truck to receive torque from an engine of the truck. The truck comprises a transmission system and retrofitted with a front axle adaptor kit, and a transfer case parking brake system adaptor kit and support mount. 
     The connector comprises a mounting face having a plurality of holes and an opening. Extending from the mounting face is an angled sidewall that extends to a spline having a distal end. The connector secures onto the transfer case. 
     The spacer assembly comprises first and second faces having a plurality of mounting holes, and a sidewall. The spacer assembly mounts onto the transfer case. 
     The automatic transmission mounting means is an automatic transmission mount comprising first and second mounting faces having a plurality of holes, and a sidewall. Extending from the sidewall is an extension mount sidewall that defines an extension mount having holes. The automatic transmission mount mounts onto the spacer assembly. 
     In one embodiment, the manual transmission mounting means is a manual transmission mount plate, a top mount plate spacer bracket, and a bottom mount plate spacer bracket. The manual transmission mount plate comprises a top edge, a bottom edge, first and second side edges, a plurality of holes, and an opening. The top mount plate spacer bracket comprises a bracket having first and second bushing spacers at opposite ends and third and fourth bushing spacers between the first and second bushing spacers. The third and fourth bushing spacers are not equal in length. The bottom mount plate spacer bracket comprises a bracket having first and second bushing spacers at opposite ends. 
     In another embodiment, the manual transmission mounting means is a manual transmission mount plate, a top mount plate spacer bracket, and a bottom mount plate spacer bracket. The manual transmission mount plate comprises a mount plate having a top edge, a bottom edge, first and second side edges, a plurality of holes and an opening. The top mount plate spacer bracket comprises a base. Extending from opposite ends of the base are first and second wing sections that each have a respective tab. The bottom mount plate spacer bracket comprises first and second wing sections. Each of the first and second wing sections have a respective tab and a lip at its distal end. 
     It is therefore one of the main objects of the present invention to provide a transmission to transfer case adaptor kit to convert two-wheel trucks to four-wheel drive, also defined as, all-wheel drive, AWD, 4WD, or 4×4 (“four by four”) to enable a drivetrain that allows all four wheels of the truck to receive torque from the truck&#39;s engine. 
     It is another object of this invention to provide a truck front axle adaptor kit to convert two-wheel trucks to four-wheel drive, which is of a durable and reliable construction. 
     It is yet another object of this invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness. 
     Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of a two-wheel drive production truck. 
         FIG. 2  is an isometric view of a prior art front axle of the two-wheel drive production truck seen in  FIG. 1 . 
         FIG. 3  is an exploded view of the replacement front differential assembly with adaptor kit mounting brackets. 
         FIG. 3A  is an isometric view of shock absorber brackets. 
         FIG. 3B  is an isometric view of a “U” shaped spring support bracket. 
         FIG. 3C  is an isometric view of a track-bar bracket. 
         FIG. 3D  is an isometric view of a dampener bracket. 
         FIG. 4  is an isometric view of the replacement front differential assembly with adaptor kit mounting brackets mounted thereon and ready to be installed onto the two-wheel drive production truck seen in  FIG. 1 . 
         FIG. 5  is an isometric view of a prior art transmission assembly and parking brake system of the two-wheel drive production truck seen in  FIG. 1 . 
         FIG. 6  is an exploded view of the transmission to transfer case adaptor kit for an automatic transmission with a prior art transfer case. 
         FIG. 6A  is an isometric view of a connector. 
         FIG. 6B  is an isometric view of a spacer assembly. 
         FIG. 6C  is an isometric view of an automatic transmission mount. 
         FIG. 7  is an exploded view of the transmission to transfer case adaptor kit for a 1988-2004 manual transmission with a prior art transfer case. 
         FIG. 7A  is an isometric view of a connector. 
         FIG. 7B  is an isometric view of a spacer assembly. 
         FIG. 7C  is an isometric view of a manual transmission mount plate. 
         FIG. 7D  is an isometric view of a top mount plate spacer bracket. 
         FIG. 7E  is an isometric view of a bottom mount plate spacer bracket. 
         FIG. 8  is an exploded view of the transmission to transfer case adaptor kit for a 2005-2010 manual transmission with a prior art transfer case. 
         FIG. 8A  is an isometric view of a connector. 
         FIG. 8B  is an isometric view of a spacer assembly. 
         FIG. 8C  is an isometric view of a manual transmission mount plate. 
         FIG. 8D  is an isometric view of a top mount plate spacer bracket. 
         FIG. 8E  is an isometric view of a bottom mount plate spacer bracket. 
         FIG. 9  is an isometric view of the transmission to transfer case adaptor kit installed onto the prior art two-wheel drive production truck seen in  FIG. 1 . 
         FIG. 10  is an isometric view of a prior art transfer case. 
         FIG. 10A  is an isometric view of a prior art transfer case hub. 
         FIG. 11  is an exploded view of the transfer case parking brake system adaptor kit and support mount. 
         FIG. 12  is an isometric view of the transfer case hub. 
         FIG. 13  is an isometric view of a parking brake system adaptor kit mounting bracket. 
         FIG. 14  is an isometric view of the parking brake system adaptor kit mounting plate. 
         FIG. 15  is an isometric view of the parking brake system adaptor kit shaft guide. 
         FIG. 16  is an isometric view of the parking brake system adaptor kit support mount plate. 
         FIG. 17  is an isometric view of the parking brake system adaptor kit support mount bar. 
         FIG. 18  is an isometric view of the transfer case parking brake system adaptor kit and support mount partly assembled to be installed onto the prior art two-wheel drive production truck seen in  FIG. 1 . 
         FIG. 19  is an isometric view of the transfer case parking brake system adaptor kit and support mount installed onto the prior art two-wheel drive production truck seen in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, the present invention is a transmission to transfer case adaptor kit and is generally referred to with numeral  300 . It can be observed that it basically includes transfer case  310 , connector  330 , and spacer assembly  350 . 
     Seen in  FIG. 1  is a two-wheel drive production truck  200 . For purposes of illustration, two-wheel drive production truck  200  is an “ISUZU N-series” two-wheel drive medium duty truck produced by Isuzu, and specifically an “NPR” model. Two-wheel drive production truck  200  is a production vehicle or production truck that is mass-produced as an identical model, offered for sale to the public, and able to be legally driven on public roads (street legal). In a preferred embodiment, two-wheel drive production truck  200  “ISUZU N-series” two-wheel drive medium duty truck is between the years 1988-2016. 
     Seen in  FIG. 2  is prior art front axle  220  of two-wheel drive production truck  200 . With prior art front axle  220 , a drivetrain of two-wheel drive production truck  200  only allows its rear wheels to receive torque from its engine. 
     Seen in  FIG. 3  is an exploded view of front axle adaptor kit  10 . Replacing prior art front axle  220  is front differential assembly  20  with adaptor kit mounting brackets. Specifically, mounted onto front differential assembly  20  are shock absorber brackets  30 , spring support brackets  70 , track-bar bracket  110 , and dampener bracket  130 . For purposes of illustration, front differential assembly  20  is from “FORD SUPER DUTY” four-wheel drive series trucks, and specifically from “F-250” through “F-550” models that are mass-produced as identical models, offered for sale to the public, and able to be legally driven on public roads (street legal). In a preferred embodiment, front differential assembly  20  is from “FORD SUPER DUTY” four-wheel drive series trucks between the years 1999-2012. Front differential assembly  20  comprises axle housing  22 , front differential  24 , and axles  26 . 
     As seen in  FIG. 3A , shock absorber bracket  30  comprises sidewall  32  having hole  60 , and cutout  34  extending between distal ends  36  and  38 . In a preferred embodiment, cutout  34  is concavely shaped to mount onto an outside diameter of axle housing  22 . Extending from distal end  36  is angled edge  40  that extends to upper perimeter edge  42 . Upper perimeter edge  42  extends to end  44 . Extending from end  44  is upper sloped edge  46  that continues to upper rounded edge  48 , which extends to rear edge  50 . Extending from rear edge  50  is lower rounded edge  52  that continues to lower sloped edge  54 , which extends to lower corner  56 . Lower perimeter edge  58  extends from lower corner  56  to distal end  38 . 
     As seen in  FIG. 3B , spring support bracket  70  comprises interior mount wall  72  mounted onto base  82 . Extending from interior mount wall  72  are upper mount wall  74  and lower mount wall  76  that terminate at distal edges  78  and  80  respectively. Base  82  has ends  84  and  86 , and lateral ends  88  and  90 . Also mounted onto base  82  is spring support mount wall  92  having upper mount wall  94  and lower mount wall  96  with distal edges  98 , and  100  and holes  102  and  104  respectively. 
     As seen in  FIG. 3C , track-bar bracket  110  comprises first and second cutouts  112 , each extending between respective distal ends  114  and  116 . In a preferred embodiment, first and second cutouts  112  are concavely shaped to mount onto the outside diameter of axle housing  22 . Extending from distal ends  114  and  116  are lateral walls  118 , each extending to respective corner sections  120 . Extending between corner sections  120  is top wall  122  having hole  124 . 
     As seen in  FIG. 3D , dampener bracket  130  comprises interior mount wall  132  mounted onto base  170 . Extending from interior mount wall  132  are corner sections  142 , and  144  seen in  FIG. 4 . Extending from corner sections  142  and  144  are lower wall  136  and upper wall  134  that terminate at distal edges  140  and  138  respectively. Base  170  has ends  172  and  174 , and lateral ends  176  and  178 . Also mounted onto base  170  is interior wall  154  that terminates at distal edge  158  and has hole  162 . Extending from interior wall  154  is base wall  150 , which continues to exterior wall  152  that terminates at distal edge  156  and has hole  160 . 
     Seen in  FIG. 4  is an isometric view of the replacement front differential assembly  20  with adaptor kit mounting brackets mounted thereon and ready to be installed onto the two-wheel drive production truck seen in  FIG. 1 . Specifically, mounted onto front differential assembly  20  are shock absorber brackets  30 , which in a preferred embodiment are the same, spring support bracket  70 , track-bar bracket  110 , and dampener bracket  130 . 
     In a preferred embodiment, a driver side shock absorber bracket  30  is positioned between a driver side axle  26  and front differential  24 , and is welded onto axle housing  22 . Dampener bracket  130  is positioned at a first predetermined distance from front differential  24 , and is welded onto axle housing  22 . Track-bar bracket  110  is positioned at a second predetermined distance from front differential  24 , and is welded onto axle housing  22 . Spring support bracket  70  is positioned at a third predetermined distance from front differential  24 , and is welded onto axle housing  22 . A passenger side shock absorber bracket  30  is positioned at a fourth predetermined distance from front differential  24 , and is welded onto axle housing  22 . The fourth predetermined distance is greater than the third predetermined distance. The third predetermined distance is greater than the second predetermined distance. The second predetermined distance is greater than the first predetermined distance. 
     The replacement front differential assembly  20  with adaptor kit mounting brackets converts a two-wheel drive production truck to four-wheel drive enabling a drivetrain that allows all four wheels of the truck to receive torque from an engine of the truck, whereby the truck has a transmission system and is retrofitted with a transfer case. 
     Shock absorber brackets  30 , spring support bracket  70 , track-bar bracket  110 , and dampener bracket  130  may be manufactured from separate metal components, welded together. In a preferred embodiment, shock absorber brackets  30 , spring support bracket  70 , track-bar bracket  110 , and dampener bracket  130 , are each manufactured as single embodiments. 
     Seen in  FIG. 5  is prior art transmission assembly  230  of two-wheel drive production truck  200 . With prior art transmission assembly  230 , a drivetrain of two-wheel drive production truck  200  only allows its rear wheels to receive torque from its engine. 
     Seen in  FIG. 6  is an exploded view of transmission to transfer case adaptor kit  300  for an automatic transmission of two-wheel drive production truck  200 . To secure onto prior art transmission assembly  230  is transmission to transfer case adaptor kit  300  comprising transfer case  310 , connector  330 , and spacer assembly  350 . 
     Transfer case  310  comprises housing  312  having mounting face  314 . Protruding from mounting face  314  is a plurality of bolts  316 . Transfer case  310  further comprises driveshaft mount  318  and aperture  320 . For purposes of illustration, transfer case  310  is from “FORD SUPER DUTY” four-wheel drive series trucks, and specifically from “F-250” through “F-550” models that are mass-produced as identical models, offered for sale to the public, and able to be legally driven on public roads (street legal). In a preferred embodiment, transfer case  310  is from “FORD SUPER DUTY” four-wheel drive series trucks between the years 1999-2012. Transmission to transfer case adaptor kit  300  for an automatic transmission of two-wheel drive production truck  200  also comprises automatic transmission mount  370  as automatic transmission mounting means. 
     As seen in  FIG. 6A , connector  330  comprises mounting face  332  having a plurality of holes  334  and opening  336 . Extending from mounting face  332  is angled sidewall  338  that extends to spline  340  having distal end  342 . 
     As seen in  FIG. 6B , spacer assembly  350  comprises faces  352  and  356  having a plurality of mounting holes  354  and  358  respectively to receive mounting bolts there through, not show, and sidewall  360 . 
     As seen in  FIG. 6C , automatic transmission mount  370  comprises mounting faces  372  and  378  having a plurality of holes  374  to receive mounting bolts there through, not show, and sidewall  376 . Extending from sidewall  376  is extension mount sidewall  384  that defines extension mount  380  having holes  382  to also receive its respective mounting bolts, not show. 
     Seen in  FIG. 7  is an exploded view of transmission to transfer case adaptor kit  300  for a 1988-2004 manual transmission of two-wheel drive production truck  200 . To secure onto prior art transmission assembly  230  is transmission to transfer case adaptor kit  300  comprising transfer case  310 , connector  330 , and spacer assembly  350 . Transmission to transfer case adaptor kit  300  for a 1988-2004 manual transmission of two-wheel drive production truck  200  also comprises manual transmission mount plate  390 , top mount plate spacer bracket  410 , and bottom mount plate spacer bracket  420  as manual transmission mounting means. 
     Seen in  FIG. 7A  is connector  330 . 
     Seen in  FIG. 7B  is spacer assembly  350   
     As seen in  FIG. 7C , manual transmission mount plate  390  comprises top edge  392 , bottom edge  394 , and side edges  396  and  398 . Manual transmission mount plate  390  further comprises a plurality of holes  400  and  404 , and opening  402 . 
     As seen in  FIG. 7D , top mount plate spacer bracket  410  comprises bracket  412  having bushing spacers  414  at opposite ends and bushing spacers  416  between bushing spacers  414 , whereby bushing spacers  416  are not equal in length. 
     As seen in  FIG. 7E , bottom mount plate spacer bracket  420  comprises bracket  422  having bushing spacers  424  at opposite ends. 
     Seen in  FIG. 8  is an exploded view of transmission to transfer case adaptor kit  300  for a 2005-2010 manual transmission of two-wheel drive production truck  200 . To secure onto prior art transmission assembly  230  is transmission to transfer case adaptor kit  300  comprising transfer case  310 , connector  330 , and spacer assembly  350 . Transmission to transfer case adaptor kit  300  for a 2005-2010 manual transmission of two-wheel drive production truck  200  also comprises manual transmission mount plate  430 , top mount plate spacer bracket  450 , and bottom mount plate spacer bracket  460  as manual transmission mounting means. 
     Seen in  FIG. 8A  is connector  330 . 
     Seen in  FIG. 8B  is spacer assembly  350   
     As seen in  FIG. 8C , manual transmission mount plate  430  comprises mount plate  432  having top edge  434 , bottom edge  436 , and side edges  437  and  438 . Manual transmission mount plate  430  further comprises a plurality of holes  440  and opening  442 . 
     As seen in  FIG. 8D , top mount plate spacer bracket  450  comprises base  452 . Extending from opposite ends of base  452  are wing sections  454  that each have a respective tab  456 . 
     As seen in  FIG. 8E , bottom mount plate spacer bracket  460  comprises wing sections  462 , each has a respective tab  464  and a lip  466  at its distal end. 
     Seen in  FIG. 9  is an isometric view of transmission to transfer case adaptor kit  300  for an automatic transmission installed onto two-wheel drive production truck  200  seen in  FIG. 1 . Specifically, secured onto prior art transmission assembly  230  is transmission to transfer case adaptor kit  300  comprising transfer case  310 , connector  330 , spacer assembly  350 , and automatic transmission mount  370 . Transmission to transfer case adaptor kit  300  converts a two-wheel drive production truck to four-wheel drive enabling a drivetrain that allows all four wheels of the truck to receive torque from an engine of the truck, whereby the truck has a transmission system and is retrofitted with a front axle adaptor kit, and a transfer case parking brake system adaptor kit and support mount. 
     Seen in  FIG. 10  is transfer case  310 , as seen in  FIG. 6 , with prior art transfer case hub  500  mounted thereon. 
     As seen in  FIG. 10A , prior art transfer case hub  500  comprises housing  502  having base end  504  and distal end  506 . Fixedly secure within distal end  506  is bearing  508 . 
     As seen in  FIG. 11 , transfer case parking brake system adaptor kit and support mount  510  comprises transfer case hub  520 , mounting bracket  540 , mounting plate  560 , shaft guide  580 , mount plate  610 , mount bar  630 , and L-plates  650 . As best illustrated herein, each L-plate  650  comprises sidewall  652  having holes  654 . Sidewall  652  extends to bend  656 . Extending from bend  656  is base wall  658  having respective holes  660 . Secured onto mounting plate  560  is brake system  600  having lever  602 . 
     As seen in  FIG. 12 , prior art transfer case hub  500  seen in  FIG. 10A  has been modified, whereby a predetermined exterior section from housing  502  has been removed resulting in transfer case hub  520 . Transfer case hub  520  comprises housing  522  having base end  524  and distal end  526 . Extending from distal end  526  is sidewall  530  having ends  532  and  534 . Fixedly secure within end  534  is bearing  528 . 
     As seen in  FIG. 13 , mounting bracket  540  comprises sidewall  542  having edges  544  and  546 . Sidewall  542  has first and second bends  548 , and terminates at first and second respective ends  550 . Affixed at first and second ends  550  are end bushing spacers  552 . Positioned between end bushing spacers  552  is at least one bushing spacer  554 . In a preferred embodiment, end bushing spacers  552  and at least one bushing spacer  554  extend from edge  544  to edge  546 . 
     As seen in  FIG. 14 , mounting plate  560  comprises plate  562  having top edge  564 , bottom edge  566 , and side edges  568  and  570 . Mounting plate  560  further comprises a plurality of holes  572  and  574 , and opening  576 . 
     As seen in  FIG. 15 , shaft guide  580  comprises sidewall  582  defined between faces  584  and  586 . Shaft guide  580  further comprises a plurality of holes  588 , and opening  590 . Shaft guide  580  mounts onto mounting plate  560  between it and brake system  600 . 
     As seen in  FIG. 16 , mount plate  610  comprises top face  612  having slots  614  to receive mounting bolts. Top face  612  extends to bend  616 . Extending from bend  616  is face  618  having respective slots  620 , also to receive mounting bolts, and cutout  622 . 
     As seen in  FIG. 17 , mount bar  630  comprises bar  632  having base ends  634  and  636 , and top ends  638  and  640 . A first distance between base ends  634  and  636  is longer than a second distance between top ends  638  and  640 . Base ends  634  and  636  each comprise holes  642  to receive mounting bolts, not seen, and bar  632  comprises mount holes  644  to also receive mounting bolts, seen in  FIG. 19 . 
     As seen in  FIG. 18 , transfer case parking brake system adaptor kit and support mount  510  are partly assembled to be installed onto the prior art two-wheel drive production truck seen in  FIG. 1 , whereby transfer case hub  520  and mounting bracket  540  are mounted onto transfer case  310 , and mounting plate  560  is mounted onto transfer case hub  520  and mounting bracket  540 . Brake system  600  having lever  602  is mounted onto mounting plate  560 , whereby shaft guide  580  mounts onto mounting plate  560  between it and brake system  600 . 
     As seen in  FIG. 19 , transfer case parking brake system adaptor kit and support mount  510  is installed onto the prior art two-wheel drive production truck seen in  FIG. 1 , whereby transfer case hub  520  and mounting bracket  540  are mounted onto transfer case  310 , and mounting plate  560  is mounted onto transfer case hub  520  and mounting bracket  540 . Brake system  600  having lever  602  is mounted onto mounting plate  560 , whereby shaft guide  580  mounts onto mounting plate  560  between it and brake system  600 . Mount plate  610  mounts onto mount bar  630  and mounting plate  560 , and L-plates  650 , seen in  FIG. 11 , secure mount bar  630  to a frame section of the prior art two-wheel drive production truck seen in  FIG. 1 . 
     The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.