# US 9,039,560 B2 · Flow-formed differential case assembly > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,039,560 B2 - Document ID: US9039560B2 - Status: Granted - Kind: B2 - Application number: 14/100,095 - Filed: 2013-12-09 - Published: 2014-04-03 - Granted: 2015-05-26 - Earliest claimed: 2010-07-01 - Assignees: Metal Forming & Coining Corporation - Applicants: Metal Forming & Coining Corporation - Inventors: Timothy J. Cripsey; Robert J. Herston - Web page: https://patentgrep.com/patent/US9039560B2 ## CPC - F16H 48/40: characterised by features of the rotating cases - F16H 48/08: comprising bevel gears - F16H 48/38: Constructional details (the outer casing comprising the differential and supporting input and output shafts F16H57/037) - F16H 2048/085: {characterised by shafts or gear carriers for orbital gears} - F16H 2048/087: {characterised by the pinion gears, e.g. their type or arrangement} - F16H 2048/382: {Methods for manufacturing differential gearings} - Y10T 74/2186: Gear casings - Y10T 74/2188: Axle and torque tubes - F16H: GEARING - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A differential case assembly includes a differential case and a pinless gear assembly. The differential case has an open end and a side wall with an interior surface. The pinless gear assembly includes a retainer insert and a side gear with a shaft extending outwardly therefrom. The retainer insert is disposed adjacent the interior surface of the side wall. The retainer insert defines at least a portion of an aperture that receives an end of the shaft to align the gear assembly within the differential case. ## Claims ### Claim 1 A differential case assembly, comprising: a differential case having an open end and a side wall with an interior surface; a pinless gear assembly including a retainer insert and a side gear with an integral cylindrical shaft extending outwardly therefrom, the retainer insert disposed adjacent the interior surface of the side wall, the retainer insert defining at least a portion of an aperture, and an end of the cylindrical shaft received in the aperture to align the gear assembly within the differential case; and a receptacle formed on the interior surface of the side wall, the receptacle including a recess for receiving the retainer insert. ### Claim 2 (depends on 1) The differential case assembly of claim 1, wherein the differential case is flow formed. ### Claim 3 (depends on 1) The differential case assembly of claim 1, further comprising an end cap disposed in the open end of the differential case. ### Claim 4 (depends on 3) The differential case assembly of claim 3, wherein the retainer insert is disposed adjacent the end cap. ### Claim 5 (depends on 3) The differential case assembly of claim 3, wherein the retainer insert is integral with the end cap. ### Claim 6 (depends on 3) The differential case assembly of claim 3, further comprising a ring gear having a lip that axially retains the end cap in the differential case. ### Claim 7 (depends on 1) The differential case assembly of claim 1, wherein the aperture is entirely defined by the retainer insert. ### Claim 8 (depends on 1) The differential case assembly of claim 1, wherein the retainer insert has an arcuate rear surface disposed adjacent the interior surface of the side wall. ### Claim 9 (depends on 8) The differential case assembly of claim 8, wherein a gap is defined between the interior surface of the side wall and the arcuate rear surface of the retainer insert. ### Claim 10 (depends on 1) The differential case assembly of claim 1, further comprising a washer disposed between the side gear and the interior surface of the differential case, the shaft of the side gear disposed through the washer. ### Claim 11 (depends on 1) The differential case assembly of claim 1, wherein the pinless gear assembly further includes an other side gear disposed opposite the side gear in the differential case. ### Claim 12 (depends on 1) The differential case assembly of claim 1, wherein a length of the shaft is less than a thickness of the side gear. ### Claim 13 (depends on 1) The differential case assembly of claim 1, wherein the pinless gear assembly further comprises a pinion gear that cooperates with the side gear. ### Claim 14 (depends on 1) The differential case assembly of claim 1, wherein the differential case is flow formed and the receptacle is a flow formed feature. ### Claim 15 (depends on 1) The differential case assembly of claim 1, wherein the recess is one of a slot and a groove flow formed in the interior surface of the differential case. ### Claim 16 (depends on 1) The differential case assembly of claim 1, wherein the recess has a receiving surface that corresponds with a shape of the cylindrical shaft. ### Claim 17 A differential case assembly, comprising: a differential case having an open end and a side wall with an interior surface; a pinless gear assembly including a retainer insert and a side gear with an integral cylindrical shaft extending outwardly therefrom, the retainer insert disposed adjacent the interior surface of the side wall, the retainer insert defining at least a portion of an aperture, and an end of the cylindrical shaft received in the aperture to align the gear assembly within the differential case; and an end cap disposed in the open end of the differential case, the retainer insert integral with the end cap. ### Claim 18 A differential case assembly, comprising: a differential case having an open end and a side wall with an interior surface; a pinless gear assembly including a retainer insert and a side gear with an integral cylindrical shaft extending outwardly therefrom, the retainer insert disposed adjacent the interior surface of the side wall, the retainer insert defining at least a portion of an aperture, and an end of the cylindrical shaft received in the aperture to align the gear assembly within the differential case; an end cap disposed in the open end of the differential case, the retainer insert integral with the end cap; and a ring gear having a lip that axially retains the end cap in the differential case.