Patent ID: 7819040

Claim:
A method for making a differential gear casing for use in a differential housing of a vehicle axle, the method comprising: flow forming a first blank about an associated central axis to provide a first casing half having a generally hemispherical portion, a shaft journal portion extending from the hemispherical portion adjacent one axial extremity thereof along its central axis, and a radial flange extending from the hemispherical portion adjacent the other axial extremity thereof along its central axis; forming a second blank about an associated central axis to provide a second casing half having a generally hemispherical portion, a shaft journal portion extending from the hemispherical portion thereof adjacent one axial extremity thereof along its central axis, a radial flange extending from its hemispherical portion at a location toward the other axial extremity thereof along its central axis, and the hemispherical portion including an axial projection having a round cylindrical shape extending axially from the radial flange thereof in a direction away from the journal portion of the second casing half; forming the first casing half to provide an interior locating surface of a round cylindrical shape adjacent the hemispherical portion thereof; forming the axial projection of the second casing half to provide an exterior locating surface of a round cylindrical shape; forming the radial flanges of the first and second casing halves to provide aligned fastener holes into which fasteners can be inserted to secure the casing halves to each other with the locating surfaces thereof contacting each other to provide positioning of the central axes in alignment with each other.