Two-speed disconnecting awd systems with pinion coupler

A rear drive module for a vehicle comprising:

• an input hub configured to receive power;
• a clutch drum;
• a torque transfer coupling configured to selectively transfer power between the input hub and the clutch drum when the torque transfer coupling is in an engaged condition, wherein the input hub is decoupled from the clutch drum when the torque transfer coupling is in a disengaged condition;
• a hypoid pinion shaft non-rotatably coupled to the clutch drum;
• a hypoid pinion gear non-rotatably coupled to the hypoid pinion shaft wherein the hypoid pinion gear and the clutch drum rotate together;
• a main ring gear meshingly engaged with the hypoid pinion gear;
• a differential comprising:
• a differential housing, a differential shaft non-rotatably coupled to the differential housing, opposing pinion gears rotatably connected together by a pinion shaft which is mechanically connected to the differential housing, opposing first and second side gears in meshing engagement with the pinion gears such that power can be transferred from the differential housing to the pinion gears and then to the first and second side gears;
• a first output shaft non-rotatably coupled to the first side gear;
• a second output shaft non-rotatably coupled to the second side gear;
• a planetary gear set comprising a sun gear non-rotatably coupled to a sun shaft which is non-rotatably coupled to the main ring gear, a planetary ring gear disposed radially outwardly of the sun gear, and a planetary carrier assembly comprising a planetary carrier rotatably supporting one or more planet gears thereon, wherein the planetary carrier is engaged with the planet gears for rotation together and the planet gears rotate between the sun gear and the planetary ring gear during rotation of the planetary carrier;
• and
• a shift collar splined to the differential shaft such that the shift collar rotates with the differential shaft while being axially slidable relative thereto, the shift collar is axially slidable between a 4HI position connecting the sun shaft to the differential shaft for transferring power received from the hypoid pinion gear to the differential housing and a 4LO position connecting the planetary carrier to the differential shaft for transferring power received from the planetary carrier to the differential housing, wherein the 4HI position is axially spaced apart from the 4LO position.

A rear drive module for a vehicle comprising:

• an input hub configured to receive power;
• a clutch drum;
• a torque transfer coupling configured to selectively transfer power between the input hub and the clutch drum when the torque transfer coupling is in an engaged condition, wherein the input hub is decoupled from the clutch drum when the torque transfer coupling is in a disengaged condition;
• a hypoid pinion shaft non-rotatably coupled to the clutch drum;
• a hypoid pinion gear non-rotatably coupled to the hypoid pinion shaft wherein the hypoid pinion gear and the clutch drum rotate together;
• a main ring gear meshingly engaged with the hypoid pinion gear;
• a differential comprising:
• a differential housing configured to rotate in response to rotation of the main ring gear, a differential shaft non-rotatably coupled to the differential housing, opposing pinion gears rotatably connected together by a pinion shaft which is mechanically connected to the differential housing, opposing first and second side gears in meshing engagement with the pinion gears such that power can be transferred from the differential housing to the pinion gears and then to the first and second side gears;
• a first output shaft non-rotatably coupled to the first side gear;
• and
• a second output shaft non-rotatably coupled to the second side gear;
• wherein the torque transfer coupling further comprises a friction clutch including a plurality of friction plates which are repositionable in an axial direction between the engaged condition coupling the clutch drum to the input hub and the disengaged condition decoupling the clutch drum from the input hub, a hydraulic piston configured to selectively apply pressure to the friction plates in the axial direction to reposition the friction plates to the engaged condition, and a return spring configured to bias the friction plates towards the disengaged condition;
• and
• wherein the return spring disengages the friction clutch decoupling the clutch drum from the input hub by axially separating the friction plates when pressure is removed from the friction plates.