Driveline component having ring gear integrally formed with tubular drive member

A power transfer device comprising:

• a housing;
• an input member having a generally tubular shape, the input member being disposed within the housing and supported for rotation relative to the housing about a first axis;
• a pinion supported within the housing for rotation about a second axis that is transverse to the first axis;
• a support bearing;
• a power member, the power member being a single-piece body that defines a ring gear and a first tube, wherein the ring gear is meshingly engaged with the pinion and defines a bore that is concentric with the input member, wherein the first tube extends in a first axial direction from the ring gear, and wherein the first tube is coupled to the input member for transmission of rotary power therebetween;
• and
• a second tube having a first end and a second end, wherein the first end of the second tube is supported for rotation relative to the housing by the support bearing, and wherein the second end is received within the bore and fixedly coupled to the power member for common rotation.

A method of forming a power transfer device, the method comprising:

• providing a PTU housing, a support tube, an input member, and a pinion;
• forging a first body to have an annular portion and a tubular portion extending concentrically from the annular portion;
• forming a first set of gear teeth into the annular portion;
• supporting a first end of the support tube within the PTU housing for rotation relative to the PTU housing about a first axis;
• fixedly coupling a second end of the support tube to the first body;
• positioning the input member concentrically within a bore of the support tube and a bore of the first body;
• coupling the input member to the first body for common rotation about the first axis;
• and
• supporting the pinion within the PTU housing for meshing engagement with the first set of gear teeth and for rotation relative to the PTU housing about a second axis that is transverse to the first axis.