Two-speed active transfer case

A transfer case for use in a four-wheel drive motor vehicle having a powertrain and first and second drivelines, comprising:

• a housing assembly;
• an input shaft supported by said housing assembly and disposed along and rotatable about a first axis and adapted to receive drive torque from the powertrain;
• a first output shaft supported by said housing assembly and disposed along and rotatable about said first axis and adapted to be interconnected to the first driveline;
• a second output shaft supported by said housing assembly and disposed along and rotatable about a second axis and adapted to be interconnected to the second driveline;
• a transfer mechanism having a first transfer component fixed for rotation with said first output shaft about said first axis, and a second transfer component rotatably supported on said second output shaft for rotation about said second axis, said second transfer component being driven by said first transfer component;
• a range mechanism including a reduction unit and a range clutch, said reduction unit being driven at a reduced speed relative to said input shaft, said range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second position to establish a drive connection between said reduction unit and said first output shaft;
• a range shift mechanism controlling movement of said range clutch between said first and second range positions;
• a mode mechanism disposed between said second transfer component and said second output shaft, said mode mechanism including a mode clutch having a first clutch member coupled to said second transfer component, a second clutch member coupled to said second output shaft, a multi-plate clutch pack disposed between said first and second clutch members, and an apply member moveable into and out of engagement with said clutch pack;
• a mode shift mechanism for controlling movement of said apply member relative to said clutch pack so as to control the magnitude of a clutch engagement force applied to said clutch pack and concurrently control the amount of drive torque transferred from said first output shaft through said transfer mechanism and said mode clutch to said second output shaft;
• a power-operated shift actuator for controlling actuation of said mode shift mechanism;
• a splash lubrication system including a sump area defined by said housing assembly and filled with a lubricating oil;
• and
• said mode mechanism at least partially disposed in said sump area for lubricating said mode mechanism with said lubricating oil,
• wherein said transfer mechanism includes a first sprocket drivingly coupled to said first output shaft, a second sprocket rotatably supported on said second output shaft, and a power chain encircling said first and second sprockets for transferring drive torque from said first output shaft to said second sprocket,
• wherein said first clutch member is a clutch drum fixed for rotation with said second sprocket and said second clutch member is a clutch hub fixed for rotation with said second shaft, and
• wherein said splash lubrication system includes a guide housing enclosing at least a portion of said power chain and said first sprocket.

A transfer case for use in a four-wheel drive motor vehicle having a powertrain and first and second drivelines, comprising:

• a housing assembly;
• an input shaft supported by said housing assembly and disposed along and rotatable about a first axis and adapted to receive drive torque from the powertrain;
• a first output shaft supported by said housing assembly and disposed along and rotatable about said first axis and adapted to be interconnected to the first driveline;
• a second output shaft supported by said housing assembly and disposed along and rotatable about a second axis and adapted to be interconnected to the second driveline;
• a transfer mechanism having a first transfer component fixed for rotation with said first output shaft about said first axis, and a second transfer component rotatably supported on said second output shaft for rotation about said second axis, said second transfer component being driven by said first transfer component;
• a range mechanism including a reduction unit and a range clutch, said reduction unit being driven at a reduced speed relative to said input shaft, said range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second position to establish a drive connection between said reduction unit and said first output shaft;
• a range shift mechanism controlling movement of said range clutch between said first and second range positions;
• a mode mechanism disposed between said second transfer component and said second output shaft, said mode mechanism including a mode clutch having a first clutch member coupled to said second transfer component, a second clutch member coupled to said second output shaft, a multi-plate clutch pack disposed between said first and second clutch members, and an apply member moveable into and out of engagement with said clutch pack;
• a mode shift mechanism for controlling movement of said apply member relative to said clutch pack so as to control the magnitude of a clutch engagement force applied to said clutch pack and concurrently control the amount of drive torque transferred from said first output shaft through said transfer mechanism and said mode clutch to said second output shaft;
• a power-operated shift actuator for controlling actuation of said mode shift mechanism, wherein said power-operated shift actuator includes a shift shaft aligned for rotation about a third axis, an electric motor for rotating said shift shaft, a range actuator driven by said shift shaft for causing said range shift mechanism to move said range clutch between its first and second range positions, and a mode actuator driven by said shift shaft for causing said mode shift mechanism to move said apply member between first and second mode positions relative to said clutch, said apply member operable in said first mode position to transfer a first magnitude of drive torque through said clutch pack to said second output shaft and further operable in said second mode position to transfer a second magnitude of drive torque through said clutch pack to said second output shaft;
• and
• a splash lubrication system including a sump area defined by said housing assembly and filled with a lubricating oil,
• wherein said mode mechanism is at least partially disposed in said sump area for lubricating said mode mechanism with said lubricating oil.