Snap-action arrangement for transfer case synchronizer

In a gear synchronizer assembly comprising a gear member rotatable on a transmission shaft, said gear member including external spline teeth and having a conical portion formed thereon with an external conical surface, a blocker ring mounted on said gear member external conical surface having an internal conical surface for frictional engagement therewith, a hub member fixed mounted on said shaft for rotation therewith and having a cylindrical hub portion encircling said blocker ring, said hub member formed with external spline teeth, a clutch sleeve encircling said hub portion and having internal spline teeth in continual engagement with said hub portion external spline teeth, said clutch sleeve being axially movable by a shifting arrangement toward and away from said gear member such that said clutch sleeve internal spline teeth are adapted to engage with said external spline teeth of said gear member, and resilient loading means for moving said blocker ring toward said gear member during the axial shifting operation of said clutch sleeve toward said gear member to effect frictional engagement of said blocker ring internal conical surface with said gear member external conical surface, said shifting arrangement comprising a shaft rail disposed in spaced parallel relation with said shaft having forward and rearward ends, means for supporting said rail adjacent its forward and rearward ends for permitting axial reciprocal movement of said rail during selected modes of operation of said synchronizer assembly, said shifting arrangement further comprising a shift fork assembly mounted on said rail, said shift fork assembly having a shift fork member adapted to coact with said clutch sleeve for slidable reciprocal travel along said shaft, the improvement wherein:

• said shift fork assembly including an arm portion having forward and rearward tube portions fixed thereto and extending longitudinally therefrom, said shift fork member having an apertured arm portion, a longitudinal tube having forward and rearward end faced, said tube extending through said arm portion aperture and fixed therein defining forward and aft tube portions, said tube encircling said rail and fixed thereto, a U-shaped bracket having a base portion formed with a forward flange and a rearward flange arranged substantially perpendicular to the principal axis of said rail, said flanges having aligned apertures such that said forward flange slides on said rail adjacent said forward end contact face and said rearward flange slides on said rail adjacent said rearward end contact face, a first compression coil spring concentrically disposed about said forward tube portion intermediate said forward flange and said shift fork assembly operative to bias said forward flange forwardly in a predetermined axial spaced relation from said forward end contact face, a second compression coil spring concentrically disposed about said rearward tube portion intermediate said rearward flange said shift rail rearward end support, means for axially shifting said U-shaped bracket rearwardly thereby causing said fist and second spring means to be compressed until said forward flange engages said forward end contact face, whereby upon said clutch sleeve moving from its neutral position to a position wherein said blocker ring and gear member conical surfaces are frictionally loaded by said resilient loading means developing a cone torque therebetween, whereby said blocker ring is rotated in one direction to an indexed position causing each said sleeve internal spline tooth positioned with its rearward chamfered edge engaging the chamfered edge of an opposed blocker ring external spline tooth thereby developing an index torque, and wherein upon the index torque developed in said indexed position exceeding the cone torque developed by said conical surfaces, said blocker ring is rotated in the opposite direction allowing said sleeve internal splines to pass into engagement with said gear member external splines, such that said first spring means snaps said shift fork assembly toward said shift rail rearward end resulting in said rearward end contact face contacting said bracket rearward flange allowing said sleeve internal spline teeth to readily pass through said blocker ring external spline teeth and into initial locked engagement with said gear member spline teeth, whereby said sleeve being operatively effective to complete its rearward travel into its full locked-up position by said shifting means.

In a transfer case apparatus adapted for a motor vehicle having front and rear ground engaging wheels, said apparatus including an input shaft adapted for connection to an engine of the motor vehicle, a first output shaft adapted for driving connection to the rear wheels and a second output shaft adapted for driving connection to the front wheels, gear reduction means positioned between said input shaft and said first output shaft, a synchronizer clutch assembly comprising a hub member splined to said first output shaft in axially spaced relation from a chain carrier journalled on said first output shaft, said clutch assembly having a blocker ring with an internal conical surface disposed for controlled abutment with an external conical surface on said chain carrier, said hub member including a cylindrical hub portion encircling said blocker ring formed with external spline teeth, a clutch shifting sleeve encircling said hub portion provided with internal spline teeth shiftably engaging external spline teeth on said hub portion, a plurality of circumferentially spaced strut grooves formed in said hub portion each receiving a strut therein, spring means normally biasing each said strut radially outward so as to press each said strut of said sleeve, a fork member adapted to shift said sleeve from a first disengaged two-wheel drive mode, wherein input shaft torque is transmitted only to said first output shaft, to a second engaged four-wheel drive mode wherein torque is transmitted both to said first and second output shaft, and an improved shift fork assembly for engaging said synchronizer clutch during said two wheel to four wheel shifting mode comprising;

• a shift rail disposed in spaced parallel relation with said input shaft having forward and rearward ends, means for preventing axial movement of said rail during selected modes of gear box operation, said shift fork assembly mounted on said rail, said shift fork assembly including a fork having projecting portions adapted to co-act with said synchronizer clutch sleeve for slidable reciprocal coaxial travel along said first output shaft from said two wheel drive mode to said four wheel drive mode, the improvement wherein:
• said fork having an apertured arm portion, a longitudinal tube having forward and rearward end faces, said tube extending through said fork arm portion aperture and fixed therein defining forward and aft tube portions, said tube encircling said rail and fixed thereto, a U-shaped bracket having a base portion and a forward flange and a rearward flange arranged substantially perpendicular to the principal axis of said rail, said flanges having aligned apertures such that said forward flange slides on said rail adjacent the forward end face and said rearward flange slides on said rail adjacent said tube rearward end face, a first compression coil spring concentrically disposed about said forward tube portion intermediate said forward flange and said fork arm portion so as to bias said forward flange forwardly in predetermined axial spaced relation from said forward end face, a second coil spring concentrically disposed about said shift rail intermediate said rearward flange and said shift rail rearward end, means for axially shifting said U-shaped bracket rearwardly thereby causing said first and second coil springs to be compressed until said forward flange engages said tube forward end such that said blocker ring internal conical surface and said chain carrier exterior conical surface are frictionally loaded by said struts developing a cone torque therebetween, whereby said blocker ring is rotated in one direction to an indexed position causing each said sleeve internal spline tooth positioned with its rearward chamfered edge engaging the chamfered edge of an opposed blocker ring external spline tooth thereby developing an index torque therebetween, and wherein upon the index torque developed in said indexed position exceeding the cone torque developed by said conical surfaces said blocker ring is rotated in the opposite direction allowing said sleeve internal splines to passs into engagement with said gear member external splines, such that said first spring snaps said shift fork assembly toward said shift rail rearward end resulting in said tube rearward end face contacting said bracket rearward flange allowing said sleeve internal spline teeth to readily pass through said blocker ring external spline teeth and into initial locked engagement with said chain carrier spline teeth, whereby said sleeve being operatively effective to complete its rearward travel into its full locked-up position by said shifting means placing said transfer case apparatus into its engaged four-wheel drive mode.