Differential gear assembly

A method of manufacturing a differential gear assembly, the method comprising:

• providing a housing;
• coaxially aligning a first sun gear and a second sun gear within the housing, each of the first and second sun gears having a central axis extending in a first direction;
• matingly engaging a first set of planetary gears with the first sun gear, each of the first set of planetary gears having a first axis extending in the first direction, each of the first set of planetary gears having a first axial outer surface substantially perpendicular to the first axis, the first axial outer surface facing away from the second sun gear;
• matingly engaging a second set of planetary gears with the second sun gear, wherein the first and second sets of planetary gears are in mating engagement with each other, each of the second set of planetary gears having a second axis extending in the first direction, each of the second set of planetary gears having a second axial outer surface substantially perpendicular to the second axis, the second axial outer surface facing away from the first sun gear;
• placing a first set of friction members such that each of the first set of friction members contacts the housing and a respective one of the first axial outer surfaces of the first set of planetary gears;
• and
• placing a second set of friction members such that each the second set of friction members contacts the housing and a respective one of the second axial outer surfaces of the second set of planetary gears.

A differential gear assembly, comprising:

• a housing;
• a first sun gear disposed within the housing;
• a second sun gear coaxially aligned with the first sun gear along a central axis;
• a first set of helical planetary gears in mating engagement with the first sun gear;
• a second set of helical planetary gears in mating engagement with the second sun gear and the first set of helical planetary gears;
• a preload member disposed between the first sun gear and the second sun gear;
• wherein, when in a first mode, the preload member and the first and second sets of helical planetary gears apply force along the central axis on the first and second sun gears;
• and
• wherein, when in a second mode, substantially only the preload member applies force along the central axis on the first and second sun gears.