Patent Description:
An axle assembly having a clutch collar is disclosed in <CIT>.

<CIT>, which is considered by the Examining Division of the European Patent Office as disclosing a shift mechanism falling within the wording of the pre-characterizing portion of independent claim <NUM> and an axle assembly falling within the wording of the pre-characterizing portion of independent claim <NUM>, discloses a torque transmission device that has a collar that has teeth with concave side surfaces and that is selectively engageable with a drive component. <CIT> discloses a torsion circuit in which a drive element is connected to an equalization gearbox via an intermediate gear axle and a selective shifting gear axle. <CIT> discloses a three-speed reverse change gear having a shift sleeve that is longitudinally displaceable on a drive shaft.

A shift mechanism is provided as set out in claim <NUM>.

An axle assembly is provided as set out in claim <NUM>.

The axle assembly <NUM> may provide torque to one or more traction wheel assemblies that may include a tire mounted on a wheel. The wheel may be mounted to a wheel hub that may be rotatable about a wheel axis.

One or more axle assemblies may be provided with the vehicle. As is best shown with reference to <FIG> and <FIG>, the axle assembly <NUM> may include a housing assembly <NUM>, a differential assembly <NUM>, at least one axle shaft <NUM>, an electric motor module <NUM>, and a transmission module <NUM>, and includes a drive pinion <NUM> and a shift mechanism <NUM>.

The axle housing <NUM> may receive and may support the axle shafts <NUM>. In at least one configuration, the axle housing <NUM> may include a center portion <NUM> and at least one arm portion <NUM>.

The center portion <NUM> may be disposed proximate the center of the axle housing <NUM>. As is best shown in <FIG>, the center portion <NUM> may define a cavity <NUM> that may at least partially receive the differential assembly <NUM>. A lower region of the center portion <NUM> may at least partially define a sump portion <NUM> that may contain or collect lubricant <NUM>. Lubricant <NUM> in the sump portion <NUM> may be splashed by a ring gear <NUM> of the differential assembly <NUM> and distributed to lubricate various components that may or may not be received in the housing assembly <NUM>. For instance, some splashed lubricant <NUM> may lubricate components that are received in the cavity <NUM> like the differential assembly <NUM>, bearing assemblies that rotatably support the differential assembly <NUM>, a drive pinion <NUM>, and so on, while some splashed lubricant <NUM> may be routed out of the cavity <NUM> to lubricate components located outside of the housing assembly <NUM>, such as components associated with the transmission module <NUM>, the shift mechanism <NUM>, or both.

Referring to <FIG>, one or more arm portions <NUM> may extend from the center portion <NUM>. For instance, two arm portions <NUM> may extend in opposite directions from the center portion <NUM> and away from the differential assembly <NUM>. The arm portions <NUM> may have similar configurations. For example, the arm portions <NUM> may each have a hollow tubular configuration that may extend around and may receive a corresponding axle shaft <NUM> and may help separate or isolate the axle shaft <NUM> or a portion thereof from the surrounding environment. An arm portion <NUM> or a portion thereof may or may not be integrally formed with the center portion <NUM>. It is also contemplated that the arm portions <NUM> may be omitted.

Referring primarily to <FIG>, the differential carrier <NUM> may be mounted to the center portion <NUM> of the axle housing <NUM>. The differential carrier <NUM> may support the differential assembly <NUM> and may facilitate mounting of the electric motor module <NUM>. For example, the differential carrier <NUM> may include one or more bearing supports that may support a bearing like a roller bearing assembly that may rotatably support the differential assembly <NUM>. In at least one configuration, the differential carrier <NUM> may include a mounting flange <NUM> and/or a bearing support wall <NUM>.

The mounting flange <NUM> may facilitate mounting of the electric motor module <NUM>. As an example, the mounting flange <NUM> may be configured as a ring that may extend around the axis <NUM>. In at least one configuration, the mounting flange <NUM> may include a set of fastener holes that may be configured to receive fasteners that may secure the electric motor module <NUM> to the mounting flange <NUM>.

The bearing support wall <NUM> may support bearings that may rotatably support other components of the axle assembly <NUM>. For example, the bearing support wall <NUM> may support a bearing that may rotatably support the drive pinion <NUM>, a bearing that may rotatably support a rotor of the electric motor module <NUM>, or both. The bearing support wall <NUM> may extend in an axial direction away from the axle housing <NUM> and may extend around the axis <NUM>. The bearing support wall <NUM> may define a hole that may extend along or around the axis <NUM> and receive the drive pinion <NUM> and the bearings that rotatably support the drive pinion <NUM>. The bearing support wall <NUM> may be integrally formed with the differential carrier <NUM> or may be a separate component that is fastened to the differential carrier <NUM>.

Referring to <FIG>, the differential assembly <NUM> may be at least partially received in the center portion <NUM> of the housing assembly <NUM>. The differential assembly <NUM> may be rotatable about a differential axis <NUM> and may transmit torque to the axle shafts <NUM> and wheels. The differential assembly <NUM> may be operatively connected to the axle shafts <NUM> and may permit the axle shafts <NUM> to rotate at different rotational speeds in a manner known by those skilled in the art. The differential assembly <NUM> may have a ring gear <NUM> that may have teeth that mate or mesh with the teeth of a gear portion of a drive pinion <NUM>. Accordingly, the differential assembly <NUM> may receive torque from the drive pinion <NUM> via the ring gear <NUM> and transmit torque to the axle shafts <NUM>.

The drive pinion <NUM> may operatively connect the transmission module <NUM> to the differential assembly <NUM>. As such, the drive pinion <NUM> may transmit torque between the differential assembly <NUM> and the transmission module <NUM>. In at least one configuration, the drive pinion <NUM> is rotatable about the axis <NUM> and may be rotatably supported inside another component, such as the bearing support wall <NUM>.

Referring primarily to <FIG> and <FIG>, the drive pinion <NUM> may optionally include or may be coupled to a drive pinion extension <NUM>. The drive pinion extension <NUM> may increase the axial length of the drive pinion <NUM>. In at least one configuration, the drive pinion extension <NUM> may be a separate component from the drive pinion <NUM> and may be coupled to the drive pinion <NUM> such that the drive pinion extension <NUM> is rotatable about the axis <NUM> with the drive pinion <NUM>. In addition, the drive pinion extension <NUM> may be fixedly positioned with respect to the drive pinion <NUM> such that the drive pinion extension <NUM> may not move along the axis <NUM> with respect to the drive pinion <NUM>. It is also contemplated that the drive pinion extension <NUM> may be integrally formed with the drive pinion <NUM>, in which case the drive pinion <NUM> may be a one-piece unitary component having a greater axial length.

In at least one configuration, the drive pinion extension <NUM> may extend from a first end <NUM> to a second end <NUM> and may include a socket <NUM> and the spline <NUM>. The socket <NUM> may extend from the first end <NUM> and may receive the drive pinion <NUM>. The second end <NUM> may be received inside and may be rotatably supported by a support bearing <NUM>. The spline <NUM>, if provided, may facilitate coupling of the drive pinion extension <NUM> to a shift collar <NUM> that may be moveable along the axis <NUM> as will be discussed in more detail below.

Referring to <FIG>, the axle shafts <NUM> may transmit torque from the differential assembly <NUM> to corresponding wheel hubs and wheels. Two axle shafts <NUM> may be provided such that each axle shaft <NUM> extends through a different arm portion <NUM> of axle housing <NUM>. The axle shafts <NUM> may extend along and may be rotatable about an axis, such as the differential axis <NUM>. Each axle shaft <NUM> may have a first end and a second end. The first end may be operatively connected to the differential assembly <NUM>. The second end may be disposed opposite the first end and may be operatively connected to a wheel. Optionally, gear reduction may be provided between an axle shaft <NUM> and a wheel.

Referring to <FIG>, the electric motor module <NUM>, which may also be referred to as an electric motor, may be mounted to the differential carrier <NUM> and may be operatively connectable to the differential assembly <NUM>. For instance, the electric motor module <NUM> may provide torque to the differential assembly <NUM> via the transmission module <NUM> and the drive pinion <NUM> as will be discussed in more detail below. The electric motor module <NUM> may be primarily disposed outside the differential carrier <NUM>. In addition, the electric motor module <NUM> may be axially positioned between the axle housing <NUM> and the transmission module <NUM>. In at least one configuration, the electric motor module <NUM> may include a motor housing <NUM>, a coolant jacket <NUM>, a stator <NUM>, a rotor <NUM>, and at least one rotor bearing assembly <NUM>. The electric motor module <NUM> may also include a motor cover <NUM>.

The motor housing <NUM> may extend between the differential carrier <NUM> and the motor cover <NUM>. The motor housing <NUM> may be mounted to the differential carrier <NUM> and the motor cover <NUM>. For example, the motor housing <NUM> may extend from the mounting flange <NUM> of the differential carrier <NUM> to the motor cover <NUM>. The motor housing <NUM> may extend around the axis <NUM> and may define a motor housing cavity <NUM>. The motor housing cavity <NUM> may be disposed inside the motor housing <NUM> and may have a generally cylindrical configuration. The bearing support wall <NUM> of the differential carrier <NUM> may be located inside the motor housing cavity <NUM>. Moreover, the motor housing <NUM> may extend continuously around and may be spaced apart from the bearing support wall <NUM>. In at least one configuration, the motor housing <NUM> may have an exterior side <NUM>, an interior side <NUM>, a first end surface <NUM>, and a second end surface <NUM>.

The exterior side <NUM> may face away from the axis <NUM> and may define an exterior or outside surface of the motor housing <NUM>.

The interior side <NUM> may be disposed opposite the exterior side <NUM> and may face toward the axis <NUM>. The interior side <NUM> may be disposed at a substantially constant radial distance from the axis <NUM> in one or more configurations.

The first end surface <NUM> may extend between the exterior side <NUM> and the interior side <NUM>. The first end surface <NUM> may be disposed at an end of the motor housing <NUM> that may face toward the differential carrier <NUM>. For instance, the first end surface <NUM> may be disposed adjacent to the mounting flange <NUM> of the differential carrier <NUM> and may engage or contact the mounting flange <NUM>.

The second end surface <NUM> may be disposed opposite the first end surface <NUM>. As such, the second end surface <NUM> may be disposed at an end of the motor housing <NUM> that may face toward the motor cover <NUM> and may engage or contact the motor cover <NUM>.

The coolant jacket <NUM> may help cool or remove heat from the stator <NUM>. The coolant jacket <NUM> may be received in the motor housing cavity <NUM> of the motor housing <NUM> and may engage the interior side <NUM> of the motor housing <NUM>. The coolant jacket <NUM> may extend axially (e.g., in a direction along the axis <NUM>) between the differential carrier <NUM> and the motor cover <NUM>. For example, the coolant jacket <NUM> may extend axially from the differential carrier <NUM> to the motor cover <NUM>. In addition, the coolant jacket <NUM> may extend around the axis <NUM> and around the stator <NUM>. Accordingly, the stator <NUM> may be at least partially received in and may be encircled by the coolant jacket <NUM>. The coolant jacket <NUM> may extend in a radial direction from the stator <NUM> to the interior side <NUM> of the motor housing <NUM>. In at least one configuration, the coolant jacket <NUM> may include a plurality of channels through which coolant may flow.

The stator <NUM> may be received in the motor housing cavity <NUM>. The stator <NUM> may be fixedly positioned with respect to the coolant jacket <NUM>. For example, the stator <NUM> may extend around the axis <NUM> and may include stator windings that may be received inside and may be fixedly positioned with respect to the coolant jacket <NUM>.

The rotor <NUM> may extend around and may be rotatable about the axis <NUM>. In addition, the rotor <NUM> may extend around and may be supported by the bearing support wall <NUM>. The rotor <NUM> may be received inside the stator <NUM>, the coolant jacket <NUM>, and the motor housing cavity <NUM> of the motor housing <NUM>. The rotor <NUM> may be rotatable about the axis <NUM> with respect to the differential carrier <NUM> and the stator <NUM>. In addition, the rotor <NUM> may be spaced apart from the stator <NUM> but may be disposed in close proximity to the stator <NUM>.

One or more rotor bearing assemblies <NUM> may rotatably support the rotor <NUM>. For example, a rotor bearing assembly <NUM> may extend around and receive the bearing support wall <NUM> of the differential carrier <NUM> and may be received inside of the rotor <NUM>. The rotor <NUM> may be operatively connected to the drive pinion <NUM>. For instance, a coupling such as a rotor output flange <NUM> may operatively connect the rotor <NUM> to the transmission module <NUM>, which in turn may be operatively connectable to the drive pinion <NUM>.

The motor cover <NUM> may be mounted to the motor housing <NUM> and may be disposed opposite the axle housing <NUM> and the differential carrier <NUM>. For example, the motor cover <NUM> may be mounted to the second end surface <NUM> of the motor housing <NUM>. The motor cover <NUM> may be spaced apart from and may not engage the differential carrier <NUM>. The motor cover <NUM> may be provided in various configurations. In at least one configuration, the motor cover <NUM> may include a first side <NUM> and a second side <NUM>. The first side <NUM> may face toward and may engage the motor housing <NUM>. The second side <NUM> may be disposed opposite the first side <NUM>. The second side <NUM> may face away from the motor housing <NUM>. The motor cover <NUM> may also include a motor cover opening through which the drive pinion <NUM> may extend. The motor cover <NUM> may be integrated with the transmission module <NUM> or may be a separate component.

Referring to <FIG> and <FIG>, the transmission module <NUM> may transmit torque between the electric motor module <NUM> and the differential assembly <NUM>. As such, the transmission module <NUM> may be operatively connectable to the electric motor module <NUM> and the differential assembly <NUM>. In at least one configuration, the transmission module <NUM> may include a first transmission housing <NUM>, a second transmission housing <NUM>, and a transmission <NUM>. The first transmission housing <NUM> and the second transmission housing <NUM> may cooperate to define a transmission housing cavity <NUM> that may receive the transmission <NUM>.

The first transmission housing <NUM> may be mounted to the electric motor module <NUM>. For instance, the first transmission housing <NUM> may be mounted to the second side <NUM> of the motor cover <NUM>. As such, the motor cover <NUM> may separate the first transmission housing <NUM> from the motor housing <NUM>.

The second transmission housing <NUM> may be mounted to the first transmission housing <NUM>. For instance, the first transmission housing <NUM> may be mounted to and may engage or contact a side of the first transmission housing <NUM> that may face away from the motor cover <NUM>. As such, the first transmission housing <NUM> may separate the second transmission housing <NUM> from the motor cover <NUM>.

The transmission <NUM> may be operatively connected to the electric motor. In at least one configuration and as is best shown in <FIG>, the transmission <NUM> may be configured as a countershaft transmission that includes a set of drive pinion gears <NUM>, and may include a first countershaft gear set <NUM>, and optionally a second countershaft gear set <NUM>.

The set of drive pinion gears <NUM> may be received in the transmission housing cavity <NUM> and may be arranged along the axis <NUM> between the first transmission housing <NUM> and the second transmission housing <NUM>. The set of drive pinion gears <NUM> may include a plurality of gears, some of which may be selectively coupled to the drive pinion <NUM>. In the configuration shown, the set of drive pinion gears <NUM> includes a first gear <NUM>, a second gear <NUM>, a third gear <NUM>, and a fourth gear <NUM>; however, it is to be understood that a greater or lesser number of gears may be provided.

The first gear <NUM> may extend around the axis <NUM> and may be disposed proximate the first transmission housing <NUM>. In at least one configuration, the first gear <NUM> may have a through hole that may receive the drive pinion <NUM>, an extension of the drive pinion <NUM> like the drive pinion extension <NUM>, or both. The first gear <NUM> may have a plurality of teeth that may be arranged around and may extend away from the axis <NUM>. The teeth of the first gear <NUM> may contact and may mate or mesh with teeth of a first countershaft gear that may be provided with the first countershaft gear set <NUM> and the second countershaft gear set <NUM> as will be discussed in more detail below. The first gear <NUM> may be operatively connected to the rotor <NUM> of the electric motor module <NUM> such that the rotor <NUM> and the first gear <NUM> are rotatable together about the axis <NUM>. For example, the first gear <NUM> may be fixedly positioned with respect to the rotor <NUM> or fixedly coupled to the rotor <NUM> such that the first gear <NUM> is not rotatable about the axis <NUM> with respect to the rotor <NUM>. It is contemplated that the first gear <NUM> may be fixedly mounted to or integrally formed with the rotor output flange <NUM>. As such, the first gear <NUM> may be continuously connected to the rotor <NUM> such that the first gear <NUM> and the rotor <NUM> may be rotatable together about the axis <NUM> but may not be rotatable with respect to each other. It is also contemplated that the first gear <NUM> may be selectively coupled to the drive pinion <NUM> or drive pinion extension <NUM>, such as with a shift collar. In addition, the first gear <NUM> may be decoupled from the drive pinion <NUM> and may be rotatable with respect to the drive pinion <NUM>. As such, a clutch or shift collar <NUM> may not connect the first gear <NUM> to the drive pinion <NUM> or the drive pinion extension <NUM>. The drive pinion extension <NUM>, if provided, may be received inside the first gear <NUM> and may be spaced apart from the first gear <NUM>. In at least one configuration, the first gear <NUM> may be axially positioned along the axis <NUM> between the second gear <NUM> and the electric motor module <NUM>.

Referring to <FIG> and <FIG>, the second gear <NUM> may extend around the axis <NUM>. In at least one configuration, the second gear <NUM> may have a through hole that may receive the drive pinion <NUM>, the drive pinion extension <NUM>, or both. The second gear <NUM> may have a plurality of teeth that may be arranged around and may extend away from the axis <NUM>. The teeth of the second gear <NUM> may contact and may mate or mesh with teeth of a second countershaft gear that may be provided with the first countershaft gear set <NUM> and the second countershaft gear set <NUM> as will be discussed in more detail below. As is best shown in <FIG>, the second gear <NUM> may also have inner gear teeth <NUM> that may extend toward the axis <NUM> and may be received in the through hole. The second gear <NUM> may have a different diameter than the first gear <NUM>. For example, the second gear <NUM> may have a larger diameter than the first gear <NUM> as is best shown in <FIG>. In at least one configuration, the second gear <NUM> may be axially positioned along the axis <NUM> between the first gear <NUM> and the third gear <NUM>. The drive pinion <NUM> or drive pinion extension <NUM>, if provided, may be received inside the second gear <NUM> and may be spaced apart from the second gear <NUM> in one or more configurations.

Referring to <FIG> and <FIG>, the third gear <NUM> may extend around the axis <NUM>. In at least one configuration, the third gear <NUM> may have a through hole that may receive the drive pinion <NUM>, the drive pinion extension <NUM>, or both. The third gear <NUM> may have a plurality of teeth that may be arranged around and may extend away from the axis <NUM>. The teeth of the third gear <NUM> may contact and may mate or mesh with teeth of a third countershaft gear that may be provided with the first countershaft gear set <NUM> and the second countershaft gear set <NUM> as will be discussed in more detail below. As is best shown in <FIG>, the third gear <NUM> may also have inner gear teeth <NUM> that may extend toward the axis <NUM> and may be received in the through hole. The third gear <NUM> may have a different diameter than the first gear <NUM> and the second gear <NUM>. For example, the third gear <NUM> may have a larger diameter than the first gear <NUM> and the second gear <NUM> as is best shown in <FIG>. In at least one configuration, the third gear <NUM> be axially positioned along the axis <NUM> between the second gear <NUM> and the fourth gear <NUM>. The drive pinion <NUM> or drive pinion extension <NUM>, if provided, may be received inside the third gear <NUM> and may be spaced apart from the third gear <NUM> in one or more configurations.

Referring to <FIG> and <FIG>, the fourth gear <NUM> may extend around the axis <NUM>. In at least one configuration, the fourth gear <NUM> may have a through hole that may receive the drive pinion <NUM>, the drive pinion extension <NUM>, or both. The fourth gear <NUM> may have a plurality of teeth that may be arranged around and may extend away from the axis <NUM>. The teeth of the fourth gear <NUM> may contact and may mate or mesh with teeth of a fourth countershaft gear that may be provided with the first countershaft gear set <NUM> and the second countershaft gear set <NUM> as will be discussed in more detail below. As is best shown in <FIG>, the fourth gear <NUM> may also have inner gear teeth <NUM> that may extend toward the axis <NUM> and may be received in the through hole. The fourth gear <NUM> may have a different diameter than the first gear <NUM>, the second gear <NUM>, and the third gear <NUM>, such as a larger diameter. In at least one configuration, the fourth gear <NUM> be axially positioned along the axis <NUM> further from the electric motor module <NUM> than the first gear <NUM>, the second gear <NUM>, and the third gear <NUM>. As such, the fourth gear <NUM> may be axially positioned proximate or adjacent to a side of the second transmission housing <NUM> that is disposed opposite the first transmission housing <NUM>. The drive pinion <NUM> or drive pinion extension <NUM> may be received inside the fourth gear <NUM> and may be spaced apart from the fourth gear <NUM> in one or more configurations.

Referring to <FIG>, thrust bearings <NUM> may optionally be provided between members of the set of drive pinion gears <NUM>, between the first transmission housing <NUM> and the set of drive pinion gears <NUM>, between the second transmission housing <NUM> and the set of drive pinion gears <NUM>, or combinations thereof. For instance, a first thrust bearing <NUM> may be axially positioned between the first transmission housing <NUM> and the first gear <NUM>, a second thrust bearing <NUM> may be axially positioned between the first gear <NUM> and the second gear <NUM>, a third thrust bearing <NUM> may be axially positioned between the second gear <NUM> and the third gear <NUM>, a fourth thrust bearing <NUM> may be axially positioned between the third gear <NUM> and the fourth gear <NUM>, and a fifth thrust bearing <NUM> may be axially positioned between the fourth gear <NUM> and the second transmission housing <NUM>.

The first countershaft gear set <NUM> may be received in the transmission housing cavity <NUM> and may be in meshing engagement with the set of drive pinion gears <NUM>. The first countershaft gear set <NUM> may be rotatable about a first countershaft axis <NUM>. The first countershaft axis <NUM> may be disposed parallel or substantially parallel to the axis <NUM> in one or more embodiments. The first countershaft gear set <NUM> may include a first countershaft <NUM> and a plurality of gears. In the configuration shown, the plurality of gears of the first countershaft gear set <NUM> include a first countershaft gear <NUM>, a second countershaft gear <NUM>, a third countershaft gear <NUM>, and a fourth countershaft gear <NUM>; however, it is contemplated that a greater number of countershaft gears or a lesser number of countershaft gears may be provided.

The first countershaft <NUM> may be rotatable about the first countershaft axis <NUM>. For instance, the first countershaft <NUM> may be rotatably supported on the first transmission housing <NUM> and the second transmission housing <NUM> by corresponding bearing assemblies <NUM>. For example, first and second bearing assemblies <NUM> may be located near opposing first and second ends the first countershaft <NUM>, respectively. The first countershaft <NUM> may support and be rotatable with the first countershaft gear <NUM>, the second countershaft gear <NUM>, the third countershaft gear <NUM>, and the fourth countershaft gear <NUM>.

The first countershaft gear <NUM> may be fixedly disposed on the first countershaft <NUM> or fixedly mounted to the first countershaft <NUM>. As such, the first countershaft gear <NUM> may rotate about the first countershaft axis <NUM> with the first countershaft <NUM> and may not be rotatable with respect to the first countershaft <NUM>. For example, the first countershaft gear <NUM> may have a hole that may receive the first countershaft <NUM> and may be fixedly coupled to the first countershaft <NUM>. The first countershaft gear <NUM> may extend around the first countershaft axis <NUM> and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis <NUM>. The teeth of the first countershaft gear <NUM> may contact and may mate or mesh with the teeth of the first gear <NUM>. In at least one configuration, the first countershaft gear <NUM> may be axially positioned along the first countershaft axis <NUM> between the first transmission housing <NUM> and the second countershaft gear <NUM> of the first countershaft gear set <NUM>.

The second countershaft gear <NUM> may be fixedly disposed on the first countershaft <NUM> or fixedly mounted to the first countershaft <NUM>. As such, the second countershaft gear <NUM> may rotate about the first countershaft axis <NUM> with the first countershaft <NUM> and may not be rotatable with respect to the first countershaft <NUM>. For example, the second countershaft gear <NUM> may have a hole that may receive the first countershaft <NUM> and may be fixedly coupled to the first countershaft <NUM>. The second countershaft gear <NUM> may extend around the first countershaft axis <NUM> and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis <NUM>. The teeth of the second countershaft gear <NUM> may contact and may mate or mesh with the teeth of the second gear <NUM>. The second countershaft gear <NUM> may have a different diameter than the first countershaft gear <NUM> and the third countershaft gear <NUM>. In at least one configuration, the second countershaft gear <NUM> may be axially positioned along the first countershaft axis <NUM> between the first countershaft gear <NUM> of the first countershaft gear set <NUM> and the third countershaft gear <NUM> of the first countershaft gear set <NUM>.

The third countershaft gear <NUM> may be fixedly disposed on the first countershaft <NUM> or fixedly mounted to the first countershaft <NUM>. As such, the third countershaft gear <NUM> may rotate about the first countershaft axis <NUM> with the first countershaft <NUM> and may not be rotatable with respect to the first countershaft <NUM>. For example, the third countershaft gear <NUM> may have a hole that may receive the first countershaft <NUM> and may be fixedly coupled to the first countershaft <NUM>. The third countershaft gear <NUM> may extend around the first countershaft axis <NUM> and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis <NUM>. The teeth of the third countershaft gear <NUM> may contact and may mate or mesh with the teeth of the third gear <NUM>. The third countershaft gear <NUM> may have a different diameter than the first countershaft gear <NUM> and the second countershaft gear <NUM>. In at least one configuration, the third countershaft gear <NUM> may be axially positioned along the first countershaft axis <NUM> between the second countershaft gear <NUM> of the first countershaft gear set <NUM> and the fourth countershaft gear <NUM> of the first countershaft gear set <NUM>.

The fourth countershaft gear <NUM> may be fixedly disposed on the first countershaft <NUM> or fixedly mounted to the first countershaft <NUM>. As such, the fourth countershaft gear <NUM> may rotate about the first countershaft axis <NUM> with the first countershaft <NUM> and may not be rotatable with respect to the first countershaft <NUM>. For example, the fourth countershaft gear <NUM> may have a hole that may receive the first countershaft <NUM> and may be fixedly coupled to the first countershaft <NUM> or may be integrally formed with the first countershaft <NUM>. The fourth countershaft gear <NUM> may extend around the first countershaft axis <NUM> and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis <NUM>. The teeth of the fourth countershaft gear <NUM> may contact and may mate or mesh with the teeth of the fourth gear <NUM>. The fourth countershaft gear <NUM> may have a different diameter than the first countershaft gear <NUM>, the second countershaft gear <NUM>, and the third countershaft gear <NUM>. In at least one configuration, the fourth countershaft gear <NUM> may be axially positioned along the first countershaft axis <NUM> further from the electric motor module <NUM> than the third countershaft gear <NUM> of the first countershaft gear set <NUM>.

The second countershaft gear set <NUM>, if provided, may be received in the transmission housing cavity <NUM> and may be rotatable about a second countershaft axis <NUM>'. The second countershaft axis <NUM>' may be disposed parallel or substantially parallel to the axis <NUM> and the first countershaft axis <NUM> in one or more embodiments. The second countershaft gear set <NUM> may generally be disposed on an opposite side of the axis <NUM> from the first countershaft gear set <NUM> or may be disposed such that the first countershaft axis <NUM> and the second countershaft axis <NUM>' may be disposed at a common radial distance from the axis <NUM>. The first and second countershaft gear sets <NUM>, <NUM> may be positioned at any suitable rotational angle or position about the axis <NUM>.

The second countershaft gear set <NUM> may have the same or substantially the same configuration as the first countershaft gear set <NUM>. For example, the second countershaft gear set <NUM> may include a second countershaft <NUM>' that may be analogous to or may have the same structure as the first countershaft <NUM>. In addition, the second countershaft gear set <NUM> may include a plurality of gears that are rotatable with the second countershaft <NUM>'. In the configuration shown, the plurality of gears of the second countershaft gear set <NUM> include a first countershaft gear <NUM>', a second countershaft gear <NUM>', a third countershaft gear <NUM>', and a fourth countershaft gear <NUM>'; however, it is contemplated that a greater number of gears or a lesser number of gears may be provided. The first countershaft gear <NUM>', second countershaft gear <NUM>', third countershaft gear <NUM>', and the fourth countershaft gear <NUM>' of the second countershaft gear set <NUM> may be analogous to or may have the same structure as the first countershaft gear <NUM>, second countershaft gear <NUM>, third countershaft gear <NUM>, and the fourth countershaft gear <NUM>, respectively, of the first countershaft gear set <NUM>. The first countershaft gear <NUM>', second countershaft gear <NUM>', third countershaft gear <NUM>', and the fourth countershaft gear <NUM>' may be arranged along and may be rotatable about a second countershaft axis <NUM>' rather than the first countershaft axis <NUM> and may be fixed to the second countershaft <NUM>' rather than the first countershaft <NUM>.

The first gear <NUM> and the first countershaft gears <NUM>, <NUM>' may provide a different gear ratio than the second gear <NUM> and the second countershaft gears <NUM>, <NUM>', the third gear <NUM> and the third countershaft gears <NUM>, <NUM>', and the fourth gear <NUM> and the fourth countershaft gears <NUM>, <NUM>'. Gear ratios may be provided that are greater than <NUM>:<NUM>, less than <NUM>:<NUM>, equal (i.e., <NUM>:<NUM>), or combinations thereof.

The teeth of the drive pinion gears and the countershaft gears may be of any suitable type. As a non-limiting example, the meshing teeth of the members of the set of drive pinion gears <NUM>, the gears of the first countershaft gear set <NUM>, and the gears of the second countershaft gear set <NUM> may have a helical configuration.

Referring primarily to <FIG>, the shift mechanism <NUM> may selectively connect the transmission module <NUM> and the drive pinion <NUM>. For example, the shift mechanism <NUM> may operatively connect a member of the set of drive pinion gears <NUM> to the drive pinion <NUM> to provide torque at a desired gear ratio, and hence may change the torque transmitted between the electric motor module <NUM> and the differential assembly <NUM>. The shift mechanism <NUM> may couple one member of the set of drive pinion gears <NUM> at a time to the drive pinion <NUM>. The member of the set of drive pinion gears <NUM> that is coupled to the drive pinion <NUM> may be rotatable about the axis <NUM> with the drive pinion <NUM>.

The shift mechanism <NUM> may be received in or partially received in a shift mechanism housing cavity <NUM>, which is best shown in <FIG> and <FIG>. The shift mechanism housing cavity <NUM> may be partially defined by the second transmission housing <NUM> and may be disposed proximate an end of the axle assembly <NUM>. Referring to <FIG> and <FIG>, a cover <NUM> may be mounted on the end of the second transmission housing <NUM> to help enclose the shift mechanism housing cavity <NUM>. The cover <NUM> is removed in <FIG>.

The shift mechanism <NUM> may have any suitable configuration. In at least one configuration such as is shown in <FIG> and <FIG>, the shift mechanism <NUM> includes a shift collar <NUM>, an actuator <NUM>, and an adjuster mechanism <NUM> and may include a detent linkage <NUM> and a linkage <NUM>.

The shift collar <NUM> is rotatable about the axis <NUM> with the drive pinion <NUM>. In addition, the shift collar <NUM> is moveable along the axis <NUM> with respect to the drive pinion <NUM>. The shift collar <NUM> may selectively connect a member of the set of drive pinion gears <NUM> to the drive pinion <NUM> as will be discussed in more detail below. The shift collar <NUM> may be at least partially received in the shift mechanism housing cavity <NUM> and may be extendable through components of the transmission <NUM>, such as the set of drive pinion gears <NUM>. In at least one configuration, the shift collar <NUM> may include a first end <NUM>, a second end <NUM>, a shift collar hole <NUM>, and a shift collar spline <NUM>. The shift collar <NUM> may also include a first tubular shift collar portion <NUM>, a second tubular shift collar portion <NUM>, a first shift collar gear <NUM>, a second shift collar gear <NUM>, a threaded portion <NUM> or combinations thereof.

The first end <NUM> may face toward the drive pinion <NUM>. In addition, the first end <NUM> may be disposed adjacent to the drive pinion <NUM> or the drive pinion extension <NUM>.

The second end <NUM> may be disposed opposite the first end <NUM>. As such, the second end <NUM> may face away from the drive pinion <NUM>.

The shift collar hole <NUM> may extend along the axis <NUM> between the first end <NUM> and the second end <NUM>. In at least one configuration, the shift collar hole <NUM> may be configured as a through hole that may extend from the first end <NUM> to the second end <NUM>. The drive pinion <NUM> or the drive pinion extension <NUM> may be received inside the shift collar hole <NUM>.

The shift collar spline <NUM> may couple the shift collar <NUM> to the drive pinion <NUM> or the drive pinion extension <NUM>. The shift collar spline <NUM> may be disposed in the shift collar hole <NUM> and may be axially positioned near the first end <NUM>. The shift collar spline <NUM> may extend toward the axis <NUM> and may mate with a spline of the drive pinion <NUM> or the spline <NUM> of the drive pinion extension <NUM> that may have spline teeth that may extend away from the axis <NUM>. The mating splines may allow the shift collar <NUM> to move in an axial direction or along the axis <NUM> while inhibiting rotation of the shift collar <NUM> about the axis <NUM> with respect to the drive pinion <NUM>. Thus, the shift collar <NUM> may be rotatable about the axis <NUM> with the drive pinion <NUM> when the shift collar spline <NUM> mates with the spline of the drive pinion <NUM> or the drive pinion extension <NUM>.

The first tubular shift collar portion <NUM> may extend from the first end <NUM> toward the second end <NUM>. The first tubular shift collar portion <NUM> may have a hollow tubular configuration and may be at least partially received inside the set of drive pinion gears <NUM> of the transmission <NUM>. The first tubular shift collar portion <NUM> may have a larger outside diameter than the second tubular shift collar portion <NUM>.

The second tubular shift collar portion <NUM>, if provided, may extend from the second end <NUM> toward the first tubular shift collar portion <NUM> or to the first tubular shift collar portion <NUM>. For instance, the second tubular shift collar portion <NUM> may have a hollow tubular configuration and may be at least partially disposed outside of the set of drive pinion gears <NUM>.

The first shift collar gear <NUM> may be disposed between the first end <NUM> and the second end <NUM> of the shift collar <NUM>. In at least one configuration, the first shift collar gear <NUM> may be disposed opposite the shift collar hole <NUM> and may extend from the first tubular shift collar portion <NUM>. The first shift collar gear <NUM> may have teeth that may be arranged around the axis <NUM> and that may extend away from the axis <NUM> and away from the shift collar hole <NUM>. The shift collar spline <NUM> may be disposed opposite the first shift collar gear <NUM>. It is noted that an example of a shift collar <NUM> that has a first shift collar gear <NUM> but not a second shift collar gear <NUM> is shown in <FIG> and <FIG> while an example of a shift collar <NUM> that has a first shift collar gear <NUM> and a second shift collar gear <NUM> is shown in <FIG>.

Referring to <FIG>, the second shift collar gear <NUM>, if provided, may be spaced apart from the first shift collar gear <NUM>. The second shift collar gear <NUM> may be axially positioned between the first end <NUM> and the second end <NUM>. For instance, the second shift collar gear <NUM> may be axially positioned between the first shift collar gear <NUM> and the second tubular shift collar portion <NUM>. In at least one configuration, the second shift collar gear <NUM> may be disposed opposite the shift collar hole <NUM> and may extend from the first tubular shift collar portion <NUM>. The second shift collar gear <NUM> may have teeth that may be arranged around the axis <NUM> and that may extend away from the axis <NUM> and away from the shift collar hole <NUM>. The second shift collar gear <NUM> may have a similar configuration as the first shift collar gear <NUM> or a different configuration. For instance, the teeth of the second shift collar gear <NUM> may have a greater axial length than the teeth of the first shift collar gear <NUM> to increase torque transmission capacity, reduce shift execution time, or both as will be discussed in more detail below. The shift collar spline <NUM> may not be disposed opposite the second shift collar gear <NUM> in one or more embodiments.

The threaded portion <NUM> may be axially positioned between the first end <NUM> and the second end <NUM>. For instance, the threaded portion <NUM> may be provided with the second tubular shift collar portion <NUM> and may be axially positioned between the first tubular shift collar portion <NUM> and the second end <NUM>. The threaded portion <NUM> may be disposed on an exterior side of the second tubular shift collar portion <NUM> that may face away from the axis <NUM>. It is also contemplated that the threaded portion <NUM> may be omitted.

Referring to <FIG> and <FIG>, the actuator <NUM> is configured to move the shift collar <NUM> along the axis <NUM> to selectively connect a member of the set of drive pinion gears <NUM> to the drive pinion <NUM>. The actuator <NUM> may be of any suitable type, such as an electrical, electromechanical, or mechanical actuator. In at least one configuration, the actuator <NUM> may be mounted to the second transmission housing <NUM>. A portion of the actuator <NUM> may be rotatable about an actuator axis <NUM>. For instance, the actuator <NUM> may have an actuator shaft that may extend along the actuator axis <NUM> and may be rotatable about the actuator axis <NUM>. The actuator shaft may be operatively connected to the detent linkage <NUM>.

Referring to <FIG>, the detent linkage <NUM> may be fixedly coupled to the actuator <NUM>. For instance, the detent linkage <NUM> may be coupled to the actuator shaft and may be rotatable about the actuator axis <NUM> with the actuator shaft. The detent linkage <NUM> may define a plurality of recesses <NUM>. The recesses <NUM> may be configured to receive a detent feature <NUM>. The detent feature <NUM> may inhibit rotation of the detent linkage <NUM> about the actuator axis <NUM> when the detent feature <NUM> is received in a recess <NUM>. For example, rotation of the detent linkage <NUM> may be inhibited when the detent feature <NUM> is in a recess <NUM> and a sufficient actuation force is not provided by the actuator <NUM> to overcome the rotational resistance exerted by the detent feature <NUM>. The detent linkage <NUM> may also be fixedly positioned with respect to the linkage <NUM>. As such, the detent feature <NUM> may inhibit movement of the linkage <NUM>.

The linkage <NUM> may operatively connect the actuator <NUM> to the shift collar <NUM> and the adjuster mechanism <NUM>. In at least one configuration, the linkage <NUM> may be positioned along the actuator axis <NUM> closer to the actuator <NUM> than the detent linkage <NUM> is positioned to the actuator <NUM>. The linkage <NUM> may be coupled to the actuator <NUM> and the detent linkage <NUM> such that the linkage <NUM> may be rotatable about the actuator axis <NUM> with the actuator shaft and the detent linkage <NUM>. For example, the linkage <NUM> may be coupled to the detent linkage <NUM> with one or more fasteners <NUM>, such as pins or bolts. It is also contemplated that the detent linkage <NUM> and the linkage <NUM> may be integrally formed. In at least one configuration, the linkage <NUM> may include an opening <NUM> that may facilitate coupling of the linkage <NUM> to the adjuster mechanism <NUM>.

Referring to <FIG>, <FIG> and <FIG>, the adjuster mechanism <NUM> may connect the linkage <NUM> to the shift collar <NUM>. In addition, the adjuster mechanism <NUM> may allow the axial position of the shift collar <NUM> to be adjusted independent of operation of the actuator <NUM> or without rotating the components of the shift mechanism <NUM> like the actuator shaft, detent linkage <NUM>, and linkage <NUM> about the actuator axis <NUM>. In at least one configuration, the adjuster mechanism <NUM> includes a collar assembly <NUM>, a follower <NUM>, and an adjustment screw <NUM>. The adjuster mechanism <NUM> may also include a locking screw <NUM> and a retainer <NUM>. As is best shown in <FIG>, a first thrust bearing <NUM>, a second thrust bearing <NUM>, a retainer nut <NUM>, or combinations thereof may optionally be associated with or disposed adjacent to the adjuster mechanism <NUM>. It is also contemplated that the adjuster mechanism <NUM> may be omitted or reconfigured to omit components such as the adjustment screw <NUM>, locking screw <NUM>, and retainer <NUM>. For instance, the collar assembly <NUM> may be provided with a collar <NUM> and a shift block <NUM> that may be separate components that may be fastened together such that spacers or shims may be provided between the collar <NUM> and shift block <NUM> to adjust the axial positioning of the shift collar <NUM>. It is also contemplated that the adjuster mechanism <NUM> may be provided with other configurations, such as when a shift fork is used to operatively connect a shift collar to an actuator.

The collar assembly <NUM> may receive the shift collar <NUM>. In at least one configuration, the collar assembly <NUM> includes a collar <NUM> and a shift block <NUM>.

The collar <NUM> may extend at least partially around the axis <NUM> in the shift collar <NUM>. For instance, the collar <NUM> may be configured as a ring that may extend around the axis <NUM>. In at least one configuration, the collar <NUM> may include a first collar side <NUM>, a second collar side <NUM>, and has a collar hole <NUM>.

The first collar side <NUM> may face toward the transmission module <NUM>, the drive pinion <NUM>, or both.

The second collar side <NUM> may be disposed opposite the first collar side <NUM>. As such, the second collar side <NUM> may face away from the transmission module <NUM>, the drive pinion <NUM>, or both.

The collar hole <NUM> may extend between the first collar side <NUM> and the second collar side <NUM>. The collar hole <NUM> may be a through hole that may extend through the collar <NUM>. The shift collar <NUM> is received inside the collar hole <NUM> and may be rotatable about the axis <NUM> with respect to the collar <NUM>. For instance, the second tubular shift collar portion <NUM> may be received inside the collar hole <NUM> and may extend through the collar hole <NUM>. In at least one configuration, the collar hole <NUM> may receive a bearing assembly that may be positioned between the shift collar <NUM> and the collar <NUM>. For example, the bearing assembly may extend from an outside circumference of the second tubular shift collar portion <NUM> to the inside diameter of the collar <NUM> that defines the collar hole <NUM>.

The shift block <NUM> is fixedly positioned with respect to the collar <NUM>. The shift block <NUM> may be integrally formed with the collar <NUM> or may be provided as a separate component that is attached to the collar <NUM>. For instance, the shift block <NUM> may extend from an outside circumference of the collar <NUM>, the second collar side <NUM>, or combinations thereof. In at least one configuration and as is best shown in <FIG> and <FIG>, the shift block <NUM> defines an elongated slot <NUM> and a first hole <NUM>. The shift block <NUM> may also define a second hole <NUM>, at least one locking screw hole <NUM>, or combinations thereof.

The elongated slot <NUM> may be open in at least a direction that extends away from the axis <NUM>. The elongated slot <NUM> may receive the follower <NUM> with a clearance fit and may be configured to allow the collar assembly <NUM> to move in an axial direction or along the axis <NUM> with respect to the follower <NUM>. The elongated slot <NUM> may be longer in a direction that may extend parallel to the axis <NUM>. In at least one configuration, the elongated slot <NUM> may have a major axis <NUM> and a minor axis <NUM>.

The major axis <NUM> may extend parallel or substantially parallel to the axis <NUM>. For instance, the major axis <NUM> may extend from the first hole <NUM> toward or to the second hole <NUM>. The major axis <NUM> may have a greater length than the minor axis <NUM>. As such, the elongated slot <NUM> may extend a greater distance along the major axis <NUM> than along the minor axis <NUM>.

The minor axis <NUM> may be disposed substantially perpendicular to the major axis <NUM>. For instance, the minor axis <NUM> may extend in a substantially vertical direction from the perspective shown.

The first hole <NUM> extends from the elongated slot <NUM>. In at least one configuration, the first hole <NUM> may be a through hole that may extend through the shift block <NUM> from the elongated slot <NUM> to an exterior surface of the shift block <NUM>. In at least one configuration, the first hole <NUM> may not be threaded and may extend substantially parallel to the major axis <NUM> of the elongated slot <NUM> and may be coaxially disposed with the major axis <NUM> of the elongated slot <NUM>.

The second hole <NUM>, if provided, may be coaxially disposed with the first hole <NUM>. In the configuration shown, the second hole <NUM> is disposed closer to the shift collar <NUM> than the first hole <NUM>; however, it is contemplated that the positioning of the first hole <NUM> and the second hole <NUM> may be reversed. The second hole <NUM> may extend from the elongated slot <NUM>. In at least one configuration, the second hole <NUM> may be a through hole that may extend through the shift block <NUM> from the elongated slot <NUM> to an exterior surface of the shift block <NUM> that may be disposed opposite the first hole <NUM>. In at least one configuration, the second hole <NUM> may not be threaded and may be coaxially disposed with the first hole <NUM>. The second hole <NUM> may extend substantially parallel to the major axis <NUM> of the elongated slot <NUM> and may be coaxially disposed with the major axis <NUM> of the elongated slot <NUM>. In at least one configuration, the second hole <NUM> may have a smaller diameter than the first hole <NUM>. Alternatively, the second hole <NUM> may have the same diameter or a larger diameter than the first hole <NUM>.

One or more locking screw holes <NUM> may be spaced apart from the first hole <NUM>, the second hole <NUM>, or both. In the configuration shown, the locking screw hole <NUM> is disposed proximate the first hole <NUM> and is spaced apart from the first hole <NUM>. The locking screw hole <NUM> may receive the locking screw <NUM>. In at least one configuration, the locking screw hole <NUM> may be a blind hole, a threaded hole, or both.

The follower <NUM> may connect or couple the linkage <NUM> to the collar assembly <NUM>. As such, the follower <NUM> may help operatively connect the actuator <NUM> to the collar assembly <NUM>. In at least one embodiment, the follower <NUM> may be configured as a generally cylindrical pin that may extend along a follower axis <NUM>. The follower axis <NUM> may be disposed substantially perpendicular to the axis <NUM> and substantially perpendicular to the major axis <NUM> of the elongated slot <NUM>. A portion of the follower <NUM> may be received in the opening <NUM> of the linkage <NUM> and another portion of the follower <NUM> is received in the elongated slot <NUM>. The follower <NUM> may be sized to fit within the elongated slot <NUM> such that the follower <NUM> may be moveable in the elongated slot <NUM> along the major axis <NUM>. For instance, the follower <NUM> may have a width or diameter that may be less than the length of the major axis <NUM> of the elongated slot <NUM>, the minor axis <NUM> of the elongated slot <NUM>, or both. In at least one configuration, the follower <NUM> defines a threaded hole <NUM>. The threaded hole <NUM> may be received in the elongated slot <NUM> and may be configured to receive the adjustment screw <NUM>.

The adjustment screw <NUM> may couple the collar assembly <NUM> to the follower <NUM>. For instance, the adjustment screw <NUM> is received in the first hole <NUM> of the shift block <NUM> and the threaded hole <NUM> of the follower <NUM>. The adjustment screw <NUM> may also be receivable in the second hole <NUM> of the shift block <NUM> if a second hole <NUM> is provided. The adjustment screw <NUM> is rotatable about an adjustment screw axis <NUM>, which may be disposed substantially parallel to and may be coaxial with the major axis <NUM> of the elongated slot <NUM>. In at least one configuration and as is best shown in <FIG>, the adjustment screw <NUM> may include a head <NUM>, a threaded portion <NUM>, a first shank portion <NUM>, a second shank portion <NUM>, or combinations thereof.

The head <NUM> may be disposed proximate an end of the adjustment screw <NUM>. For instance, the head <NUM> may be disposed adjacent to the first hole <NUM> of the shift block <NUM> and may be disposed outside of the first hole <NUM>. The head <NUM> may extend away from the axis <NUM> and may protrude from the first shank portion <NUM>. In at least one configuration, the head <NUM> may include a plurality of teeth <NUM>. The teeth <NUM> may be arranged around the adjustment screw axis <NUM> and may extend away from the adjustment screw axis <NUM>. A recess or gap <NUM> may be provided between adjacent teeth <NUM>. For clarity, only some of the gaps are labeled in <FIG>.

The threaded portion <NUM> may be positioned along the adjustment screw axis <NUM> between the head <NUM> and a distal end of the adjustment screw <NUM>. The threaded portion <NUM> may be received in the elongated slot <NUM>. The threaded portion <NUM> may also be received in the threaded hole <NUM> in the follower <NUM>.

The first shank portion <NUM> may extend between the head <NUM> and the threaded portion <NUM>. The first shank portion <NUM> may be received in the first hole <NUM> of the shift block <NUM>. The first shank portion <NUM> may be rotatable in the first hole <NUM> and may or may not be threaded.

The second shank portion <NUM>, if provided, may extend between the threaded portion <NUM> and the distal end of the adjustment screw <NUM> that is disposed opposite the head <NUM>. The second shank portion <NUM> may be received in the second hole <NUM> of the shift block <NUM>. The second shank portion <NUM> may be rotatable in the second hole <NUM>. In at least one configuration, the second shank portion <NUM> may protrude out of the second hole <NUM> and may include a groove or indentation <NUM> that may receive the retainer <NUM>. Optionally, the second shank portion <NUM> may have a different diameter than the first shank portion <NUM>, such as a smaller diameter, and may be threaded or unthreaded. It is also contemplated that the second shank portion <NUM> may be omitted, such as when the second hole <NUM> is not provided.

The locking screw <NUM> may inhibit rotation of the adjustment screw <NUM>. For instance, the locking screw <NUM> may be partially received in the locking screw hole <NUM> of the shift block <NUM>. A portion of the locking screw <NUM> that protrudes from and may not be received in the locking screw hole <NUM> may engage the adjustment screw <NUM>. For example, the head of the locking screw <NUM> may engage the head <NUM> of the adjustment screw <NUM> and may be received in a gap <NUM> between adjacent teeth <NUM> of the head <NUM>. As such, the locking screw <NUM> may engage the teeth <NUM> that are disposed adjacent to the gap <NUM> in which the locking screw <NUM> is received, thereby inhibiting rotation of the adjustment screw <NUM>.

The retainer <NUM> may limit axial movement of the adjustment screw <NUM> along the adjustment screw axis <NUM>. The retainer <NUM> may inhibit removal of the adjustment screw <NUM> from the shift block <NUM>. The retainer <NUM> may have any suitable configuration. For example, the retainer <NUM> may be configured as a fastener such as a snap ring, such screw, retaining pin, washer, or the like. In at least one configuration, the retainer <NUM> may be mounted to the second shank portion <NUM> proximate the distal end of the adjustment screw <NUM>. For instance, the retainer <NUM> may be received in the indentation <NUM> in the second shank portion <NUM> and may be disposed outside of the second hole <NUM>.

Referring to <FIG>, the first thrust bearing <NUM> may facilitate rotation of the shift collar <NUM> about the axis <NUM> with respect to the collar assembly <NUM>. The first thrust bearing <NUM> may be axially positioned between the first collar side <NUM> and the shift collar <NUM>. Optionally, washers may be axially positioned adjacent to one or both sides of the first thrust bearing <NUM>.

The second thrust bearing <NUM> may facilitate rotation of the shift collar <NUM> about the axis <NUM> with respect to the collar assembly <NUM>. The second thrust bearing <NUM> may be positioned between the second collar side <NUM> and the retainer nut <NUM>. Optionally a washer may be axially positioned adjacent to one or both sides of the first thrust bearing <NUM>. For example, a washer may be provided between the second thrust bearing <NUM> and the retainer nut <NUM>.

The retainer nut <NUM> may be mounted to the shift collar <NUM>. For instance, the retainer nut <NUM> may have a threaded hole that may receive the second tubular shift collar portion <NUM> and mate with the threaded portion <NUM> of the shift collar <NUM>. The retainer nut <NUM> may inhibit axial movement of the shift collar <NUM> with respect to the collar <NUM> and may help secure the first thrust bearing <NUM> and the second thrust bearing <NUM>. It is also contemplated that the retainer nut <NUM> may be omitted and a different fastener or fastening technique may be used. For instance, a fastener like a snap ring or a press-fit fastener may replace a threaded connection.

An encoder disc <NUM> may optionally be mounted to the drive pinion <NUM> or the drive pinion extension <NUM>. In at least one configuration, the encoder disc <NUM> may be disposed adjacent to the retainer nut <NUM>. For instance, the encoder disc <NUM> may be axially positioned between the retainer nut <NUM> and a support bearing <NUM> that rotatably supports the drive pinion <NUM> or drive pinion extension <NUM>. For example, the support bearing <NUM> may be positioned between a shoulder of the drive pinion <NUM> or drive pinion extension <NUM> and the support bearing <NUM>, if provided. The encoder disc <NUM> may have detectable features such as protrusions and/or recesses that may be detectable by a sensor to detect rotation or the rotational speed of the drive pinion <NUM>.

The support bearing <NUM> may rotatably support the drive pinion <NUM> or drive pinion extension <NUM>. For instance, the drive pinion <NUM> or drive pinion extension <NUM> may be received inside and may be rotatably supported by the support bearing <NUM>, which in turn may be supported by the second transmission housing <NUM>, the cover <NUM>, or both.

The adjuster mechanism <NUM> may allow the shift collar <NUM> and the collar assembly <NUM> to be moved along the axis <NUM> to more precisely position the shift collar <NUM> with respect to the set of drive pinion gears <NUM> and their inner gear teeth. As such, the adjuster mechanism <NUM> may compensate for design tolerances, such as design tolerances that may be associated with the axial positioning of the drive pinion gears <NUM>, the detent linkage <NUM>, linkage <NUM>, shimming of the thrust bearings <NUM>, or combinations thereof. Axial alignment of the gear portion or gear portions of the shift collar <NUM> and the inner gear teeth of the set of drive pinion gears <NUM> may be adjusted, which may improve gear engagement and shifting accuracy when the shift collar <NUM> is shifted with the actuator <NUM>. Proper axial adjustment may inhibit collar kick-out or help ensure that teeth of a gear portion or gear portions of the shift collar <NUM> remain engaged with a drive pinion gear and may help reduce tooth flank wear, including when teeth flanks have crowned profiles (e.g., mating concave and convex flanks). Axial adjustment of the shift collar <NUM> may also help properly position the shift collar <NUM> in a neutral position to help ensure that the shift collar <NUM> does not engage a member of the set of drive pinion gears <NUM>. Such disengagement may help ensure that a spline of the shift collar <NUM> does not contact the spline of a drive pinion gear during synchronization and may help avoid spline damage. An example of how the adjuster mechanism <NUM> may be operated is as follows.

First, the detent feature <NUM>, which is best shown in <FIG>, may lock the detent linkage <NUM> so that the detent linkage <NUM> may be inhibited from rotating about the actuator axis <NUM> and so that the linkage <NUM> is held in a stationary position. The linkage <NUM> may then inhibit movement of the follower <NUM>.

Next, the locking screw <NUM> may be disengaged from the adjustment screw <NUM>. For instance, the locking screw <NUM> may be rotated to disengage the locking screw <NUM> from the head <NUM> of the adjustment screw <NUM>.

Next, the adjustment screw <NUM> may be rotated about the adjustment screw axis <NUM>. Rotating the adjustment screw <NUM> may cause the collar assembly <NUM> and the shift collar <NUM> to move along the axis <NUM> with respect to the follower <NUM>. An example of such movement is shown by comparing <FIG> with <FIG>. In <FIG>, the collar assembly <NUM> is shown in a nominal position in which the follower <NUM> is generally centered in the elongated slot <NUM>. Rotating the adjustment screw <NUM> in a first direction about the adjustment screw axis <NUM> may loosen the adjustment screw <NUM> with respect to the follower <NUM>, thereby actuating the collar assembly <NUM> and the shift collar <NUM> along the axis <NUM> toward the cover <NUM>, or to the right from the perspective shown and to or toward the position shown in <FIG>. Conversely, rotating the adjustment screw <NUM> in a second direction about the adjustment screw axis <NUM> that is opposite the first direction may tighten the adjustment screw <NUM> and actuate the collar assembly <NUM> and the shift collar <NUM> along the axis <NUM> away from the cover <NUM>. The adjustment screw <NUM> may be rotated to axially align the first shift collar gear <NUM> or second shift collar gear <NUM> with a member of the set of drive pinion gears <NUM>.

Finally, the locking screw <NUM> may be tightened to engage the adjustment screw <NUM>. For instance, the locking screw <NUM> may be received in the gap <NUM> in the head <NUM> of the adjustment screw <NUM> to inhibit rotation of the adjustment screw <NUM> about the adjustment screw axis <NUM> as previously discussed. The actuator <NUM> may then be subsequently used to move the shift collar <NUM> along the axis while the adjuster mechanism <NUM> may remain fixed and moves axially with the collar assembly <NUM>.

It is also contemplated that the adjuster mechanism <NUM> may be provided to adjust the axial position of a shift collar that is provided with an axle assembly having any suitable configuration. For instance, the adjuster mechanism <NUM> may be provided with an axle assembly that does not have an electric motor module <NUM> or that has a transmission module with a different configuration, such as a planetary gear configuration.

Referring to <FIG>, the actuator <NUM> may move the shift collar <NUM> along the axis <NUM> between a plurality of positions to selectively couple the shift collar <NUM> to the transmission <NUM> or to decouple the shift collar <NUM> from the transmission <NUM>. For instance, the actuator <NUM> may move the shift collar <NUM> along the axis <NUM> between the first, second, and third positions. Examples of these positions are illustrated in <FIG>, <FIG>, and <FIG>. The actuator <NUM> may also move the shift collar <NUM> along the axis <NUM> to first and second neutral positions, which are best shown in <FIG> and <FIG>. It is noted that in <FIG> only a portion of the transmission <NUM> is shown to better illustrate movement of the shift collar <NUM>. It is also noted that the shift collar <NUM> in <FIG> includes a first shift collar gear <NUM> and a second shift collar gear <NUM> unlike the configuration shown in <FIG> and <FIG>, which lacks a second shift collar gear <NUM>. In the configuration shown in <FIG> and <FIG>, the shift collar may move between the same plurality of positions but only the first shift collar gear <NUM> may couple the shift collar <NUM> to the transmission <NUM>. As a result, the shift collar in <FIG> and <FIG> may have a greater axial length, longer shift distance, longer shift time, and longer standout than the shift collar shown in <FIG>. In the examples below, reference to connecting or disconnecting a member of the set of drive pinion gears <NUM> to/from the drive pinion <NUM> includes direct and indirect connections to and disconnections from the drive pinion <NUM>. For instance, a member of the set of drive pinion gears <NUM> may be directly coupled to the drive pinion <NUM> or indirectly connected to the drive pinion <NUM> such as via the drive pinion extension <NUM>.

In <FIG>, the first shift collar gear <NUM> and the second shift collar gear <NUM> may be engageable with different members of the set of drive pinion gears <NUM> as will be discussed in more detail below. The first shift collar gear <NUM> may not connect the set of drive pinion gears <NUM> to the drive pinion <NUM> when the second shift collar gear <NUM> connects a member of the set of drive pinion gears <NUM> to the drive pinion <NUM>. Conversely, the second shift collar gear <NUM> may not connect the set of drive pinion gears <NUM> to the drive pinion <NUM> when the first shift collar gear <NUM> connects member of the set of drive pinion gears <NUM> to the drive pinion <NUM>. More specifically, in the configuration shown the first shift collar gear <NUM> may be engageable with the second gear <NUM> or the third gear <NUM> but not the first gear <NUM> or the fourth gear <NUM>. The second shift collar gear <NUM> may be engageable with the fourth gear <NUM> but not the first gear <NUM>, the second gear <NUM>, or the third gear <NUM>.

Referring to <FIG>, the shift collar <NUM> is shown in the first position. In the first position, the shift collar <NUM> may couple the second gear <NUM> to the drive pinion <NUM>. For example, the teeth of the first shift collar gear <NUM> may mesh with the inner gear teeth <NUM> of the second gear <NUM>. Torque may be transmitted from the rotor <NUM> to the first gear <NUM> such as via the rotor output flange <NUM>, from the first gear <NUM> to the first countershaft gears <NUM>, <NUM>', from the first countershaft gears <NUM>, <NUM>' to the second countershaft gears <NUM>, <NUM>' via the first and second countershafts <NUM>, <NUM>', respectively, from the second countershaft gears <NUM>, <NUM>' to the second gear <NUM>, and from the second gear <NUM> to the drive pinion <NUM> via the first shift collar gear <NUM> of the shift collar <NUM>. The second shift collar gear <NUM> may not engage the inner gear teeth <NUM>, <NUM> of the third gear <NUM> or the fourth gear <NUM>. As such, the first gear <NUM>, the third gear <NUM>, and the fourth gear <NUM> may be rotatable about the axis <NUM> with respect to the drive pinion <NUM> when the first gear ratio is provided. Torque may be provided at the first gear ratio in the first position, such as a high-speed gear ratio.

Referring to <FIG>, the shift collar <NUM> is shown in the first neutral position. In the first neutral position, the shift collar <NUM> may not couple any member of the set of drive pinion gears <NUM> to the drive pinion <NUM>. As such, the teeth of the first shift collar gear <NUM> and the teeth of the second shift collar gear <NUM> may be spaced apart from the first gear <NUM>, the second gear <NUM>, the third gear <NUM>, and the fourth gear <NUM>. The teeth of the first shift collar gear <NUM> may be axially positioned between the inner gear teeth <NUM> of the second gear <NUM> and the inner gear teeth <NUM> of the third gear <NUM>. The teeth of the second shift collar gear <NUM> may be axially positioned between the inner gear teeth <NUM> of the third gear <NUM> and the inner gear teeth <NUM> of the fourth gear <NUM>. As such, the first gear <NUM>, the second gear <NUM>, the third gear <NUM>, and the fourth gear <NUM> may be rotatable about the axis <NUM> with respect to the drive pinion <NUM> when the shift collar <NUM> is in the first neutral position and torque may not be transmitted between the transmission <NUM> and the drive pinion <NUM>. The first neutral position may be positioned between the first position shown in <FIG> and the second position shown in <FIG>.

Referring to <FIG>, the shift collar <NUM> is shown in the second position. In the second position, the shift collar <NUM> may couple the third gear <NUM> to the drive pinion <NUM>. For example, the teeth of the first shift collar gear <NUM> may mesh with the inner gear teeth <NUM> of the third gear <NUM>. Torque may be transmitted from the rotor <NUM> to the first gear <NUM> such as via the rotor output flange <NUM>, from the first gear <NUM> to the first countershaft gears <NUM>, <NUM>', from the first countershaft gears <NUM>, <NUM>' to the third countershaft gears <NUM>, <NUM>' via the first and second countershafts <NUM>, <NUM>', respectively, from the third countershaft gears <NUM>, <NUM>' to the third gear <NUM>, and from the third gear <NUM> to the drive pinion <NUM> via the first shift collar gear <NUM> of the shift collar <NUM>. The second shift collar gear <NUM> may not engage the inner gear teeth <NUM> of the third gear <NUM> or the inner gear teeth <NUM> of the fourth gear <NUM>. As such, the first gear <NUM>, the second gear <NUM>, and the fourth gear <NUM> may be rotatable about the axis <NUM> with respect to the drive pinion <NUM> when the second gear ratio is provided. Torque may be provided at the second gear ratio in the second position, such as a mid-speed gear ratio.

Referring to <FIG>, the shift collar <NUM> is shown in the second neutral position. In the second neutral position, the shift collar <NUM> may not couple any member of the set of drive pinion gears <NUM> to the drive pinion <NUM>. As such, the teeth of the first shift collar gear <NUM> and the teeth of the second shift collar gear <NUM> may be spaced apart from the first gear <NUM>, the second gear <NUM>, the third gear <NUM>, and the fourth gear <NUM>. The teeth of the first shift collar gear <NUM> and the teeth of the second shift collar gear <NUM> may be axially positioned between the inner gear teeth <NUM> of the third gear <NUM> and the inner gear teeth <NUM> of the fourth gear <NUM>. As such, the first gear <NUM>, the second gear <NUM>, the third gear <NUM>, and the fourth gear <NUM> may be rotatable about the axis <NUM> with respect to the drive pinion <NUM> when the shift collar <NUM> is in the second neutral position and torque may not be transmitted between the transmission <NUM> and the drive pinion <NUM>. The second neutral position may be positioned between the second position shown in <FIG> and the third position shown in <FIG>.

Referring to <FIG>, the shift collar <NUM> is shown in the third position. In the third position, the shift collar <NUM> may couple the fourth gear <NUM> to the drive pinion <NUM>. For example, the teeth of the second shift collar gear <NUM> may mesh with the inner gear teeth <NUM> of the fourth gear <NUM>. Torque may be transmitted from the rotor <NUM> to the first gear <NUM> such as via the rotor output flange <NUM>, from the first gear <NUM> to the first countershaft gears <NUM>, <NUM>', from the first countershaft gears <NUM>, <NUM>' to the fourth countershaft gears <NUM>, <NUM>' via the first and second countershafts <NUM>, <NUM>', respectively, from the fourth countershaft gears <NUM>, <NUM>' to the fourth gear <NUM>, and from the fourth gear <NUM> to the drive pinion <NUM> via the second shift collar gear <NUM> of the shift collar <NUM>. The first shift collar gear <NUM> may not engage the inner gear teeth <NUM> of the second gear <NUM> or the inner gear teeth <NUM> of the third gear <NUM>. As such, the first gear <NUM>, the second gear <NUM>, and the third gear <NUM> may be rotatable about the axis <NUM> with respect to the drive pinion <NUM> when the third gear ratio is provided. Torque may be provided at the third gear ratio in the third position, such as a low-speed gear ratio.

Claim 1:
A shift mechanism (<NUM>) comprising:
a shift collar (<NUM>); and
an actuator (<NUM>);
characterized in that the shift mechanism further comprises:
an adjuster mechanism (<NUM>) that includes:
a collar assembly (<NUM>) that includes:
a collar (<NUM>) that defines a collar hole (<NUM>) that receives the shift collar (<NUM>); and
a shift block (<NUM>) that is fixedly positioned with respect to the collar (<NUM>), the shift block (<NUM>) defining an elongated slot (<NUM>) and a first hole (<NUM>) that extends from the elongated slot (<NUM>);
a follower (<NUM>) that is partially received in the elongated slot (<NUM>) and that is operatively connected to the actuator (<NUM>), the follower (<NUM>) defining a threaded hole (<NUM>); and
an adjustment screw (<NUM>) that is received in the first hole (<NUM>) and the threaded hole (<NUM>) and that is rotatable about an adjustment screw axis (<NUM>) such that rotation of the adjustment screw (<NUM>) moves the collar assembly (<NUM>) and the shift collar (<NUM>) along an axis (<NUM>).