WO1997029921A1

WO1997029921A1 - Full-time transfer case with synchronized gear reduction unit

Info

Publication number: WO1997029921A1
Application number: PCT/US1997/002111
Authority: WO
Inventors: Robert J. Wilson; Randolph C. Williams; John D. Zalewski; Sanjeev K. Varma; David Sperduti
Original assignee: New Venture Gear, Inc.
Priority date: 1996-02-13
Filing date: 1997-02-13
Publication date: 1997-08-21
Also published as: DE19781584T1; GB2324842B; AU2120997A; CA2245853C; GB2324842A; BR9707420A; GB9817699D0; CA2245853A1

Abstract

A power transfer system (10) is disclosed for a four-wheel drive vehicle operable for permitting a vehicle operator to select between various full-time and part-time four-wheel drive modes. The power transfer system (10) includes a transfer case (20) equipped with a gear reduction unit (68) and a synchronized range shift mechanism (104) operable for permitting the vehicle operator to shift on-the-fly for estblishing full-time and part-time high-range and low-range four-wheel drive modes. The transfer case (20) is also equipped with an electronically-controlled slip limiting/torque-biasing arrangement including an interaxle differential (22) and a transfer clutch (44) operable for controlling the magnitude of speed differentiation and torque biasing across the interaxle differential (22).

Description

FULL-TIME TRANSFER CASE WITH SYNCHRONIZED GEAR REDUCTION UNIT

BACKGROUND OF THE INVENTION The present invention relates to a power transfer system for controlling the distribution of drive torque between the front and rear wheels of a four-wheel drive vehicle as a function of various system and operator-initiated inputs.

Due to increased consumer demand for four-wheel drive vehicles, a plethora of different power transfer systems are currently utilized for directing power (i.e., drive torque) to all four wheels of the vehicle. For example, in many "part-time" power transfer systems, a transfer case is incorporated into the driveline and is normally operable in a two-wheel drive mode for delivering drive torque to the driven wheels. When four-wheel drive is desired, a "mode" shift mechanism can be selectively actuated by the vehicle operator for directly coupling the non- driven wheels to the driven wheels for establishing a part-time four-wheel drive mode. As will be appreciated, motor vehicles equipped with such a part-time power transfer systems offer the vehicle operator the option of selectively shifting between the two-wheel drive mode during normal road conditions and the part-time four-wheel drive mode for operation under adverse road conditions. An example of a part-time transfer case is disclosed in commonly-owned U.S. Patent No. 4,770,280 to Frost.

Alternatively, it is known to use "on-demand" power transfer systems for automatically directing power to the non-driven wheels, without any input or action on the part of the vehicle operator, when traction is lost at the driven wheels. Modernly, the "on-demand" feature is incorporated into the transfer case by replacing the mode shift mechanism with a clutch assembly that is interactively associated with an electronic control system and a sensor arrangement. During normal road conditions, the clutch assembly is maintained in a non-actuated condition such that drive torque ιs only delivered to the driven wheels. However, when the sensors detect a low traction condition at the driven wheels, the clutch assembly is automatically actuated to deliver drive torque "on-demand" to the non- driven wheels. Moreover, the amount of drive torque transferred through the clutch assembly to the non-driven wheels can be varied as a function of specific vehicle dynamics, as detected by the sensor arrangement One example of such an "on-demand" power transfer system is disclosed in commonly-owned U.S. Pat. No 5,323,871 to Wilson et al wherein the electronically-controlled clutch assembly is operable for automatically controlling the amount of drive torque transferred to the non-driven wheels as a function of the wheel speed difference (i e., the wheel slip) between the driven and non-driven wheels

As a further alternative, some vehicles are equipped with full- time power transfer system having a transfer case equipped with a center differential that functions to permit interaxle speed differentiation while transferring drive torque to both of the front and rear drivelines To minimize loss of traction due to wheel slippage, full-time transfer cases are typically equipped with a slip limiting device for locking the center differential to prevent speed differentiation and, in effect, establishing a part-time four-wheel dπve mode Examples of manually-actuated differential lock-up arrangements are disclosed in commonly-owned U.S Patent No. 3,848,691 to Dolan and U.S. Patent No. 4,677,873 to Eastman An automatic differential lock-up arrangement is disclosed in commonly- owned U.S Patent No. 3,845,671 to Sharp et al. wherein an electπcally- controlled clutch assembly is actuated to lock-up the center differential when speed differentiation due to a wheel slip condition is detected as exceeding a predetermined value In addition, torque-biasing differential lock-up arrangements are disclosed in commonly-owned U.S Patent No 4,031 ,780 to Dolan et al. and U.S. Patent No. 5,046,998 to Frost, which both utilize a viscous coupling to progressively modify the torque distribution in proportion to the magnitude of the speed differentiation across the center differential Finally, electronically-controlled full-time transfer cases are disclosed in U.S. Patent No. 4,718,303 to Fogelberg and U.S Patent No. 4,860,612 to Dick et al. wherein an electromagnetic biasing clutch is provided across the center differential to controllably bias the torque delivered to the front and rear drivelines in response to wheel

To accommodate differing road surfaces and conditions, many of the above-referenced transfer cases are equipped with a gear reduction unit for providing high-range (i.e., direct drive) and low-range (i.e., reduced ratio drive) speed ratios in conjunction with the various four-wheel drive modes Most commonly, the gear reduction units used in such dual-speed transfer cases include either a layshaft arrangement or a planetary gear assembly However, in most current four-wheel drive vehicles, the transfer case can only be shifted between the four-wheel low-range drive mode and the four-wheel high-range drive mode when the motor vehicle is in a substantially non-motive condition Unfortunately, the need to stop the vehicle prior to shifting between the available four-wheel drive speed ranges is inconvenient, particularly upon encountering road conditions or surface terrain where continuation of the vehicle's rolling momentum would assist in overcoming the conditions encountered As such, gear reduction units have been designed which permit the vehicle operator to shift "on- the-fly" from the four-wheel low-range drive mode into the four-wheel high- range drive mode without stopping the vehicle. For example, U.S Pat No 5,054,335 to Andrews discloses a transfer case having a synchronized shift arrangement for a layshaft-type gear reduction unit while commonly- owned U.S Pat. No 5,346,442 to Eastman discloses a transfer case having a synchronized shift arrangement for a planetary-type gear reduction unit. However, while both designs advance the art, the need still exists to develop a gear reduction unit that can also be shifted "oπ-the-fly" from the four-wheel high-range drive mode into the four-wheel low-range drive mode In view of the fact that most modern dual-speed transfer cases are equipped with planetary-type gear reduction units, a particular need exists to develop a synchronized shift arrangement for such transfer cases to permit the vehicle operator to shift "on-the-fly" between both available four-wheel drive speed ranges

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an improved power transfer system for use in four-wheel drive vehicles having a transfer case equipped with a clutch assembly for controlling the torque delivered to the front and rear wheels in response to changing vehicle conditions

According to a preferred embodiment, the power transfer system of the present invention is operable for establishing a full-time four- wheel drive mode and includes a transfer case having a clutch assembly arranged to control speed differentiation and torque biasing across an interaxle differential, sensors for detecting and generating input signals indicative of various dynamic and operational characteristics of the vehicle, and a controller for controlling actuation of the clutch assembly in response to the sensor input signals Under normal road and tractive conditions the clutch assembly is maintained in a non-actuated condition However, upon the occurrence of traction loss, the clutch assembly is automatically actuated for limiting interaxle slip while transferring increased dπve torque to the non-slipping wheels Under a preferred control scheme the actuated condition of the clutch assembly is controllably varied between its non-actuated and fully-actuated limits as a function of the sensor input signals for automatically varying the speed differentiation and torque biasing across the interaxle differential in response to changes in the dynamic and operational characteristics of the vehicle

The power transfer system may further include means for establishing a part-time four-wheel drive mode in addition to the full-time four-wheel drive mode To this end, a mode select mechanism is provided for permitting the vehicle operator to select one of the full-time and part- time four-wheel drive modes and generate a mode signal indicative thereof The mode signal is delivered to the controller for use in controlling actuation of the clutch assembly When the part-time four-wheel drive mode is selected, the clutch assembly is fully-actuated for preventing speed differentiation across the interaxle differential and thereby delivering non-differentiated drive torque to the front and rear drivelines When the full-time four-wheel drive mode is selected, the actuated condition of the clutch assembly is controllably varied between its non-actuated and fully- actuated limits in response to the sensor input signals for automatically varying speed differentiation and torque biasing across the interaxle differential Thus, the power transfer system of the present invention offers the vehicle operator the option of selecting the specific four-wheel drive mode best-suited for operating the motor vehicle during normal or adverse road conditions as well as for off-road use

As a further feature of the present invention, the transfer case is equipped with a gear reduction unit and a synchronized range shift mechanism that permit "on-the-fly" shifting between a four-wheel high- range dπve mode and a four-wheel low-range drive mode Accordingly, the synchronized range shift mechanism permits the vehicle operator to shift the transfer case between the various full-time and part-time four- wheel high-range and low-range drive modes without stopping the vehicle The gear reduction unit can be a single-planetary device, dual-planetary device, or a layshaft arrangement A further object of the present invention is to supply one or more "operator-initiated" input signals to the controller for further controlling automatic operation of the power transfer system in response thereto Preferably the operator-initiated input signals are indicative of the position of a movable control element (i e , accelerator pedal throttle position, steering wheel, brake pedal, etc ) and are used, in conjunction with the sensor input signals, for optimizing the torque biasing across the interaxle differential BR1EF DESCRIPTION OF THE DRAWINGS Further objects, features and advantages of the present invention will become apparent to those skilled in the art from analysis of the following written description, the accompanying drawings and the appended claims in which

FIG 1 is a schematic representation of a four-wheel drive motor vehicle equipped with the power transfer system of the present invention,

FIG. 2 is a cross-sectional view of a transfer case constructed according to a preferred embodiment of the present invention and which includes a planetary gear reduction unit, a synchronized range shift mechanism an interaxle differential, a clutch assembly, a drive mechanism, and an electrically-controlled actuator,

FIG. 3 is an enlarged partial view of FIG 2 showing the planetary gear reduction unit and synchronized range shift arrangement in greater detail,

FIG 4 is also an enlarged partial view of FIG 2 showing various components of the interaxle differential and clutch assembly in greater detail, FIG 5 is a side view of a sector plate associated with the drive mechanism for controlling coordinated actuation of the synchronized range shift mechanism and the clutch assembly,

FIG 6 is a block diagram of a control system for the power transfer system of the present invention, FIG 7 is a flow chart depicting a control sequence for the operations performed by the control system of FIG 6

FIG 8 illustrates plots of relationships between wheel speed differential signals at various vehicle speed ranges and the electrical control signal supplied by the control system to the actuator for controlling the amount of torque transferred through the clutch assembly, FIG. 9 is an exemplary plot of a relationship between steering angle and a control characteristic used for modifying the speed differential signal;

FIG. 10 is a cross-sectional view of a transfer case constructed according to an alternative preferred embodiment having a layshaft-type gear reduction unit;

FIG. 11 is an enlarged partial view of FIG. 10 showing the layshaft gear reduction unit and synchronized range shift mechanism in greater detail; FIG. 12 is a side view of a sector plate used for controlling coordinated movement of the synchronized range shift mechanism and the clutch assembly;

FIG. 13 is a cross-sectional view of a transfer case constructed according to another alternative preferred embodiment equipped with a dual-planetary gear reduction unit;

FIG. 14 is an enlarged partial view of FIG. 13 showing a dual- planetary gear reduction unit and synchronized range shift mechanism;

FIG. 15 is a side view of the sector plate used for controlling movement of the synchronized range shift arrangement: and FIG. 16 is a side view of the sector plate used for controlling actuation of the clutch assembly.

DETAILED DESCRIPTION OF THE INVENTION According to the various preferred embodiments of the present invention, a power transfer system is disclosed for a four-wheel drive vehicle which includes means for permitting a vehicle operator to select between a full-time four-wheel drive mode and a part-time four- wheel drive mode. In addition, the power transfer system includes a synchronized range shift mechanism for use with a gear reduction unit that is operable for providing four-wheel low-range and high-range drive modes. Thus, the power transfer system of the present invention is adapted to permit the vehicle operator to shift "on-the-fly" between the various available full-time and part-time high-range and low-range four-wheel drive modes.

Referring now to the drawings, a drivetraiπ for a four-wheel drive vehicle is schematically shown interactively associated with a power transfer system 10 of the present invention. The motor vehicle drivetrain includes a front driveline 12 and a rear driveline 14 both drivable from a source of power, such as an engine 16, through a transmission 18 which may be of either the manual or automatic type. In the particular embodiment shown, the drivetrain is an all-wheel drive system which incorporates a transfer case 20 for transmitting drive torque from engine

16 and transmission 18 to front driveline 12 and rear driveline 14. Front driveline 12 includes a pair of front wheels 24 connected at opposite ends of a front axle assembly 26 having a front differential 28 that is coupled to one end of a front drive shaft 30, the opposite end of which is coupled to a front output shaft 32 of transfer case 20. Similarly, rear driveline 14 includes a pair of rear wheels 34 connected at opposite ends of a rear axle assembly 36 having a rear differential 38 coupled to one end of a rear drive shaft 40, the opposite end of which is interconnected to a rear output shaft 42 of transfer case 20. As will be detailed hereinafter with greater specificity, transfer case 20 is equipped with an electronically-controlled

"slip limiting/torque-biasing" arrangement including an interaxle (i.e., center) differential 22 operably interconnecting front output shaft 32 and rear output shaft 42 and a transfer clutch 44 that is operable to control the magnitude of speed differentiation and modify the torque distribution ratio across center differential 22.

Power transfer system 10 further includes an actuator 46 for actuating transfer clutch 44, a first sensor group 48 for sensing specific dynamic and operational characteristics of the motor vehicle and generating sensor input signals indicative thereof, and a controller 50 for generating a control signal in response to the sensor input signals.

Moreover, controller 50 is adapted to control the actuated condition of transfer clutch 44 by sending the control signal to actuator 46. As is schematically shown, controller 50 is also operable for illuminating a visual display 52 located within the passenger compartment for providing the vehicle operator with a visual indication of the operational status of power transfer system 10. Power transfer system 10 can optionally include a second sensor group 54 for generating one of more "operator-initiated" input signals that are indicative of the position of movable control elements under the control of the vehicle operator. The operator-initiated input signals are used for establishing control characteristics which, in combined with the sensor input signals, are used to generate control signals to further regulate the torque distribution across transfer clutch 44

Power transfer system 10 also includes a mode select mechanism 56 for permitting the vehicle operator to select one of the available full-time or part-time four-wheel drive modes In particular, controller 50 controls actuator 46 in response to a mode signal sent to controller 50 from mode select mechanism 56 that is indicative of the particular mode selected. When the full-time four-wheel drive mode is selected, controller 50 operates to continuously monitor and automatically regulate the actuated condition of transfer clutch 44 between its non- actuated and fully-actuated limits for varying the magnitude of speed differentiation and drive torque transmitted across center differential 22.

Preferably, controller 50 functions to control actuation of transfer clutch 44 so as to increase the drive torque delivered to the slower turning output shaft while concurrently decreasing the drive torque delivered to the faster turning output shaft in an amount equal to the torque capacity of transfer clutch 44 at a given actuated state. However, when the mode signal indicates that the part-time four-wheel drive mode has been selected, transfer clutch 44 is fully actuated to maintain center differential 22 in a "locked-up" condition, whereby non-differentiated power is delivered to output shafts 32 and 42. The part-time four-wheel drive mode is provided for permitting improved traction when the motor vehicle is operated off-road or on severe road conditions With particular reference now to FIGS. 2 through 4, a preferred construction for transfer case 20 will now be described. Transfer case 20 is shown to include a housing 58 formed by a series of modular sections which are suitably interconnected by a plurality of threaded fasteners 60. An input shaft 62 is shown rotatably supported in housing

58 via a bearing assembly 64. A transmission output shaft, partially shown at 66, is coupled (i.e., splined) to input shaft 62 such that both are rotatably driven by engine 16 of the motor vehicle, A planetary-type gear reduction unit, hereinafter planetary gear assembly 68, is operably installed between input shaft 62 and a mainshaft 70. As will be detailed, planetary gear assembly 68 is operable in a "high-range" drive mode for driving mainshaft 70 at a direct speed ratio (i.e., 1 :1) relative to input shaft 62. Planetary gear assembly 68 is also operable in a "low-range" drive mode for driving mainshaft 70 at a reduced speed ratio (i.e., 0.37:1) relative to input shaft 62. Finally, planetary gear assembly 68 is operable in a "Neutral" non- driven mode for interrupting the transfer of drive torque from input shaft 62 to mainshaft 70.

Planetary gear assembly 68 includes a sun gear 72 integrally formed on input shaft 62, a ring gear 74, and a plurality of pinion gears 76 (one shown) in meshed engagement with sun gear 72 and ring gear 74.

Each pinion gear 76 is rotatably joumalled on a pinion shaft 78 having its opposite end supported in a planet carrier 80. Preferably, planet carrier 80 is constructed to include fore and aft carrier rings 82 and 84, respectively, secured together by suitable fasteners (not shown). A locator disk 86 is secured to carrier ring 82 for rotation with planet carrier 80. While not critical to the present invention, it is preferable that the type of gears associated with planetary gear assembly 68 be of the helical type. That is. sun gear 72, pinion gears 76, and ring gear 74 are all formed to have helical teeth. To contain the axial loads generated due to the helical gear teeth, and facilitate relative rotation between sun gear 72 and pinion gears

76, thrust washers 88 are located between the laterally-spaced radial edge surfaces of sun gear 72 and the facing inner surfaces of locator disk 86 and aft carrier ring 84. In this manner, planet carrier 80 is axially restrained by sun gear 72 while being free to float radially for negating or substantially minimizing unbalanced torque loading thereon.

To provide means for transferring drive torque from planetary gear assembly 68 to mainshaft 70, aft carrier ring 84 is shown coupled to a tubular quill shaft 90 that, in turn, is fixed via splined connection 92 for rotation with mainshaft 70. The axial location of quill shaft 90 on mainshaft 70 is maintained by a radial locator flange 94 and a snap ring 96. As shown, a gear hub 98 is formed at the forward end of quill shaft 90 which has its external teeth 100 meshed with internal teeth 102 on aft carrier ring

84. In addition, a synchronized range shift mechanism 104 is provided in conjunction with planetary gear assembly 68 and is operable for permitting transfer case 20 to be shifted "on-the-fly" between a four-wheel low-range drive mode and a four-wheel high-range drive mode. In particular, synchronized range shift mechanism 104 includes a bell-shaped reaction member 106 having a radial plate segment 108 fixed via a splined connection 110 to ring gear 74 for rotation therewith. A thrust washer 112 and a snap ring 114 locate plate segment 108 relative to planet carrier 80. Reaction member 106 also includes a tubular segment 118 which is supported on quill shaft 90 by a pair of bearing assemblies 120. Thus, reaction member 106 is supported for relative rotation with respect to mainshaft 70.

As best seen from FIG. 3, range shift mechanism 104 includes a bi-directional synchronizer clutch apparatus 121 that is operably associated with reaction member 106 for selectively coupling ring gear 74 to either a brake plate 122 or a direct-drive hub 124. Brake plate 122 is shown fixed to housing 58 via bolts 126 while direct-drive hub 124 is shown fixed via a splined connection 128 to quill shaft 90 with a retainer ring 130 axially locating direct-drive hub 124 thereon. Synchronizer clutch apparatus 121 includes a hub 132 that is fixed via a splined connection

134 to tubular segment 118 of reaction member 106 and is axially retained thereon via a snap ring 136. Hub 132 has an outer cylindrical rim 138 on which external longitudinal splines 140 are formed Synchronizer clutch apparatus 121 also includes a plurality of struts 142 (one shown), each being retained in one of a series of circumferentially-spaced cutouts formed in outer cylindrical nm 138 of hub 132 Struts 142 are biased in a radially outward direction by a pair of energizing springs 144. Synchronizer clutch apparatus 121 also includes a range sleeve 146 having internal longitudinal splines 148 that mesh with external splines 140 on hub 132 Thus, range sleeve 146 is supported for rotation with ring gear 74 as well as for axial sliding movement on hub 132. Splines 148 include a central detent groove 150 that is provided for centering range sleeve 146 on humps 152 of struts 142 so as to define a centered "Neutral" position (designated by position line "N") Furthermore, synchronizer clutch apparatus 121 includes a first blocker πng 154 having raised blocker teeth 156 and a frusto-conical surface 158 that is supported for limited axial and rotational movement on an upper frusto-conical surface 157 of a reaction ring 159, its lower frusto-conical surface 161 retained on a frusto-conical surface 160 formed on an annular flange segment 162 of brake plate 122 Axial tangs 163 on reaction πng 159 are nested against a hub portion of brake plate 122. A second blocker ring 164 having raised blocker teeth 166 and a frusto-conical surface 168 is supported on an upper frusto- conical surface 167 of a reaction ring 169, its lower frusto-conical surface 171 retained on a frusto-conical surface 170 formed on an annular flange segment 172 of direct-drive hub 124 Axial tangs 173 on reaction ring 169 are nested against direct drive hub 124 Blocker rings 154 and 164 are rotatably restrained by nm portion 138 of hub 132 such that movement of range sleeve 146 in either direction from the centered Neutral position shown causes struts 142 to act thereon for generating a synchronizing cone torque

When it is desired to establish the low-range drive connection between input shaft 62 and mainshaft 70, range sleeve 146 is moved toward brake plate 122 Such movement causes struts 142 to act on blocker ring 154 which, in turn, causes its blocker teeth 156 to be rotatably indexed out of alignment with range sleeve splines 140, thereby preventing further axial movement of range sleeve 146 until speed synchronization between brake plate 122 and ring gear 74 is established. Once speed synchronization is complete, splines 148 on range sleeve 146 are permitted to move through blocker teeth 156 and into a position of meshed engagement with clutch teeth 174 on brake plate 122. In this position, as denoted by position line "L" in FIG. 3, the low-range drive connection is established between input shaft 62 and mainshaft 70. Such speed synchronization between ring gear 74 and brake plate 122 results in ring gear 74 being stopped or "braked" prior to movement of range sleeve 146 through blocker teeth 156. Since ring gear 74 is held stationary, rotation of input shaft 62 causes planet carrier 80 to be rotatably driven at the reduced speed ratio which, in turn, drives quill shaft 90 and mainshaft 70 at the reduced speed ratio. When it is desired to establish the high-range drive connection between input shaft 62 and mainshaft 70, range sleeve 146 is moved toward direct-drive hub 124. Such movement causes struts 142 to act on blocker ring 164 which, in turn, causes blocker teeth 166 to index and prevent further movement of range sleeve 146 until speed synchronization is established between ring gear 74 and planet carrier 80.

Upon completion of speed synchronization, spline teeth 148 of range sleeve 146 are permitted to pass through blocker teeth 166 and into a position of meshed engagement with clutch teeth 176 on direct-drive hub 124. As such, sun gear 72, ring gear 74 and pinion gears 76 are effectively locked together to rotate as a common unit. Thus, in this position, as denoted by position line "H" in FIG. 3, the high-range drive connection is established between input shaft 62 and mainshaft 70. Finally, when it is desired to shift transfer case 20 into its Neutral mode, range sleeve 146 is moved to its ("N") position. In this position, ring gear 74 is uncoupled from both brake plate 122 and direct-drive member 124.

As such, rotation of input shaft 62 and sun gear 72 causes planet gears 76 to rotate about their respective pinion shafts 78 which, in turn, causes ring gear 74 to be rotatably driven As a result, planet carrier 80 is not rotatably driven in response to rotation of sun gear 72, whereby quill shaft 90 and mainshaft 70 are also maintained in a non-driven state

To provide means for moving range sleeve 146 between its three distinct positions, synchronized range shift mechanism 104 further includes a range fork 178 having projections 180 that are retained in a groove 182 formed in range sleeve 146 Range fork 178 also includes a tubular segment 184 that is fixedly connected to a shift rail 186, the opposite ends of which are supported in sockets 188 and 190 formed in housing 58 for sliding movement relative thereto As will be described, transfer case 20 includes means for causing axial movement of shift rail 186 and, in turn, range sleeve 146 between the three above-noted positions in response to actuation of actuator 46

With particular reference now to FIGS 2 and 4, the various components associated with the slip hmiting/torque-biasing arrangement in transfer case 20 will now be described Specifically, center differential 22 is provided for mechanically coupling mainshaft 70 to front dπveshaft 30 and rear dπveshaft 40 to permit speed differentiation and distribute drive torque therebetween While any suitable differential unit is contemplated for use with transfer case 20, center differential 22 is disclosed as a single planetary gearset having a sun gear 192 connected for rotation with front output shaft 32, a ring gear 194 coupled for rotation with rear output shaft 42, and a plurality of pinion gears 196 carried by a planet carrier 198 that is coupled for rotation with mainshaft 70 Moreover, each pinion gear 196 mtermeshes with both sun gear 192 and ring gear

194 As seen, mainshaft 70 is coupled to the output of range shift mechanism 104 via its direct connection to quill shaft 90 Thus, driven rotation of mainshaft 70 causes center differential 22 to drive front and rear output shafts 32 and 42, respectively, at a predetermined speed ratio with respect to one another As is known, the torque distribution (i e , the torque split) normally delivered across center differentia! 22 to output shafts 32 and 42 is a ratio determined by the particular gear geometry associated with the mtermeshed gear components.

With continued reference to FIGS. 2 through 4, mainshaft 70 is shown to have its forward end rotatably supported by a bearing assembly 200 mounted in a piloted bore in input shaft 62. its intermediate portion rotatably supported by a bearing assembly 202 mounted in a bearing plate 204, and its rearward end rotatably supported by a bearing assembly 206 mounted in a piloted bore in rear output shaft 42. Similarly, rear output shaft 42 is rotatably supported in housing 58 by a bearing assembly 210 and front output shaft 32 is rotatably supported in housing

58 via bearing assemblies 212 and 214. Rear output shaft 42 is shown to include a radially-extending plate segment 218 that is fixedly secured to one end of a cylindrical outer drum 220. Ring gear 194 is defined by a set of gear teeth 222 formed on the inner peripheral surface of a outer drum 220 Gear teeth 222 are shown to be in constant mesh with gear teeth

224 of pinion gears 194. As is also shown, planet carrier 198 includes a pair of carrier rings 226 and 228 between which pinion gears 196 are journally supported for rotation on pins 230. Carrier ring 226 is fixed via a spiined connection 232 to mainshaft 70. Sun gear 192 is journally supported on an intermediate portion of mainshaft 70 for relative rotation with respect thereto and is integrally formed to include a gear hub 236 and an elongated shaft sleeve 238. Gear hub 236 has external gear teeth 240 formed thereon which are in constant meshed engagement with gear teeth 224 of pinion gears 196. A drive sprocket 242 is shown fixed via a splined connection 244 to shaft sleeve 238 of sun gear 192 with a pair of retaining rings 246 provided for maintaining its axial alignment with respect thereto Drive sprocket 242 drivingly engages a chain 248 coupled to a driven sprocket 250 which is coupled to, or an integral portion of, front output shaft 32. Thus, in the embodiment disclosed, planet carrier 198 is the input member of center differential 22 while sun gear 192 and ring gear

194 are its front and rear output members, respectively Transfer clutch 44 is installed within transfer case 20 for controlling speed differentiation and the resulting torque distribution between ring gear 194 and sun gear 192 of center differential 22. Transfer clutch 44 is a multi-plate friction clutch assembly and includes an inner drum 252 that is fixed via a splined connection 254 to shaft sleeve 238 for rotation with sun gear 192. In particular, inner drum 252 is formed to include an annular hub segment 256 splined to shaft sleeve 238, a web segment 258 extending radially from hub segment 256, and a cylindrical rim segment 260 formed at the opposite end of web segment 258 which extends coaxially to hub segment 256. Pressure plate 262 is splined for rotation with inner drum 252 and abuts radial flange stop 264 formed thereon. Outer drum 220 is shown to surround inner drum 252 so as to form an internal chamber 266 therebetween. Disposed within internal chamber 266 are two sets of alternately interleaved friction clutch plates that can be frictionally compressed for limiting speed differentiation and biasing the torque distribution between sun gear 192 and ring gear 194 of center differential 22. In particular, a set of inner clutch plates 268 are mounted (i.e., splined) to rim segment 260 of inner drum 252 for rotation with sun gear 192. Likewise, a set of outer clutch plates 270 are mounted (i.e., splined) to outer drum 220 for rotation with ring gear 194. The interleaved clutch plates are supported for axial sliding movement to establish frictional contact between.

With continued reference to FIGS. 2 and 4, transfer clutch 44 is shown to include a thrust mechanism 272 supported for axial sliding movement on shaft sleeve 238 and which is operable for frictionally compressing the interleaved clutch plates as a function of the clutch engagement force exerted thereon. Thrust mechanism 272 includes an annular inner bearing support 274 journally supported for sliding non- rotatable movement on shaft sleeve 238. To this end, inner bearing support 274 includes one or more axial flanges 276 that are nested within a corresponding aperture formed in a pivotable lever arm 278 for inhibiting rotation of inner bearing support 274. Thrust mechanism 272 also includes an annular outer bearing support 280 that is coupled for rotation with inner drum 252 and a bearing assembly 282 retained between inner bearing support 274 and outer bearing support 280. As seen, axial lugs 284 formed on the distal end of rim segment 260 are nested within apertures 286 in outer bearing support 280. Thus, outer bearing support 280 is supported for rotation with inner drum 252 and ring gear 194 while inner bearing support 274 is held stationary relative thereto. Buttons (not shown), are mounted on lever arm 278 and are adapted to engage inner bearing support 274 for causing sliding movement of thrust mechanism 272 in response to pivotal movement of lever arm 278. Such axial sliding movement of thrust mechanism 272 causes a clutch engagement force to be exerted by an apply plate segment 288 of outer bearing support 280 on the interleaved clutch plates. An annular return spring 290 is retained between inner drum 252 and outer bearing support 280 for normally biasing thrust mechanism 272 in a direction away from the clutch plates.

Preferably, actuator 46 is a rotary actuator 292, such as an electric gearmotor, which is operable for generating an output torque, the value of which varies as a function of the magnitude of the electrical control signal applied thereto by controller 50. To provide means for selectively controlling the magnitude of the clutch engagement force exerted on thrust mechanism 272, rotary actuator 292 is connected to a drive mechanism 294. Drive mechanism 294 is interconnected to an rotary output member 296 of rotary actuator 292 for changing its output torque into an axially-directed force used for controlling the clutch engagement force applied by lever arm 278 on thrust mechanism 272 of transfer clutch

44 as well as for controlling axial movement of range sleeve 146. In particular, drive mechanism 294 includes a sector plate 300 that is rotatably driven through a range of angular motion by output member 296 of rotary actuator 292. As will be detailed, sector plate 300 is operable for causing coordinated movement of range sleeve 146 between its three distinct range positions and controlling the magnitude of the clutch engagement force exerted on thrust mechanism 272 by lever arm 278 so as to establish the various drive modes that are available. An actuator shaft 302, supported from transfer case housing 58 for rotation about an axis 304, has one end secured in an aperture 306 formed in sector plate 300 with its opposite end coupled to output member 296 of rotary actuator 292.

To generate the desired clutch engagement force, sector plate 300 includes a mode slot 308 within which a crowned roller 310 is retained. Crowned roller 310 is fixed to a flange section 312 of lever arm 278 Lever arm 278 also includes a generally Y-shaped or forked section 314 which is bifurcated to surround mainshaft 70. The bifurcated ends of forked section 314 are retained for pivotal movement on a transverse rail 316, the ends of which are retained in suitable sockets (not shown) formed in housing 58 The contour of mode slot 308 is configured to cause controlled pivotal movement of lever arm 278 in response to rotation of sector plate 300 for generating the clutch engagement force exerted on thrust mechanism 272 of transfer clutch 44. To control axial movement of range sleeve 146, sector plate 300 also has a range slot 318 within which a range pin 320 extends. Range pin 320 is fixed to shift rail 186 As such, the contour of range slot 318 is configured to cause controlled axial movement of shift rail 186 and, in turn, range fork 178 and range sleeve

142 in response to controlled rotation of sector plate 300

From FIGS. 4 and 5, it can be seen that sector plate 300 may be rotated about axis 304 by actuator shaft 302 to any one of five distinct sector positions, as labelled "PT-H", "FT-H", "N", "FT-L", and "PT-L" As will be detailed, transfer case 20 is operable for establishing at least five distinct operative modes, namely, a part-time four-wheel high-range drive mode, a full-time four-wheel high-range drive mode, a Neutral non-driven mode, a full-time four-wheel low-range drive mode, and a part-time four- wheel low-range drive mode The particular operational mode selected is established by the position of crowned roller 310 in mode slot 308 and the position of range pin 320 in range slot 318 in response to angular position of sector plate 300. In operation, the vehicle operator selects a desired operative drive mode via mode select mechanism 56 which, in turn, signals controller 50 of the selection Thereafter, controller 50 generates an electric control signal that is applied to rotary actuator 292 for controlling the rotated position of sector plate 300 More particularly, upon selection of the part-time four-wheel high-range drive mode, the Neutral mode or the part-time four-wheel low-range drive mode, sector plate 300 is controllably rotated to each mode's predefined sector position, namely PT-H, N, or PT- L However when the full-time four-wheel high-range and low-range drive modes are selected, power transfer system 10 is operable for modulating the clutch engagement force applied to transfer clutch 44 as a function of the various sensor and operator-initiated input signals Mode select mechanism 56 can take the form of any mode selector device which is under the control of the vehicle operator for generating a mode signal indicative of the specific mode selected In one form, the mode selector device may be an array of dash-mounted push button switches

Alternatively, the mode selector device may be a manually-operable shift lever sequentially movable between a plurality positions corresponding to the available operational modes which, in conjunction with a suitable electrical switch arrangement, generates a mode signal indicating the mode selected In either form, mode select mechanism 56 offers the vehicle operator the option of deliberately choosing between the various operative drive modes.

With particular reference to FIG 5, the contour of range slot 318 and mode slot 308 are defined in greater detail In particular, the contour of range slot 318 is defined by first, second and third cam pathways 322, 324 and 326, respectively, which respectively correspond to fourth, fifth and sixth cam pathways 328, 330 and 332, respectively, associated with mode slot 308 In the PT-H sector position shown, crowned roller 310 is positioned within mode slot 308 in close proximity to the terminal end of fourth cam pathway 328 for establishing a part-time

(PT) position With crowned roller 310 in this (PT) position lever arm 278 is pivoted toward transfer clutch 44 so as to exert the maximum clutch engagement force on thrust mechanism 272 for frictionally compressing the interleaved clutch plates such that transfer clutch 44 is considered to be operating in a fully-actuated (i.e., locked-up) condition. In addition, range pin 320 is shown positioned within range slot 318 in close proximity to the terminal end of first cam pathway 322 for positioning range sleeve 146 in its high-range (H) position. Accordingly, when mode select mechanism 56 signals that the vehicle operator has selected the part-time four-wheel high-range drive mode, controller 50 sends a control signal to rotary actuator 292 for generating sufficient output torque to rotate sector plate 300 to the PT-H sector position shown. To provide means for holding sector plate 300 in its PT-H sector position, power transfer system 10 includes a brake 334, schematically shown in FIGS. 2 and 6. Brake 334 is an electrically-controlled spring-applied device that is operable in a "power-off' condition for braking inertial loads (i.e., rotation) of output member 296 of rotary actuator 292 and, in turn, actuator shaft 302. During controlled rotation of sector plate 300, an electrical signal from controller 50 maintains brake 334 in its "power-on" condition. However, once sector plate 300 has been rotated to its PT-H position, power to brake 334 is interrupted to shift it into its power-off condition, thereby locking actuator shaft 302 against rotation.

When mode select mechanism 56 signals selection of the full- time four-wheel high-range drive mode, sector plate 300 is caused to rotate about axts 304 in a first (i.e., clockwise) direction from the PT-H position shown, whereby the contour of fourth cam pathway 328 in mode slot 308 causes axial displacement of crowned roller 310 from the (PT) position toward a full-time (FT) position Such movement of crowned roller 310 causes concurrent pivotal movement of lever arm 278 in a direction away from transfer clutch 44 which permits return spring 290 to axially shift thrust mechanism 272 so as to cause a proportional decrease in the clutch engagement force exerted on interleaved clutch plates by thrust mechanism 272. During such rotation of sector plate 300, the contour of first cam pathway 322 maintains range sleeve 146 in its (H) position Moreover, once crowned roller 310 is in the (FT) position, lever arm 278 does not exert a clutch engagement force on thrust mechanism 272 and transfer clutch 44 is considered to be non-actuated, thereby permitting unrestricted speed differentiation between front and rear drivelines 12 and 14, respectively.

According to the present invention, when transfer case 20 is operating in the full-time four-wheel high-range drive mode, the electronically-controlled slip limiting/torque-biasing arrangement is active for controlling transfer clutch 44 "on-demand". Specifically, the actuated state of rotary actuator 292 is continuously monitored and varied in accordance with specific predefined relationships established based on the current value of the sensor input signals. Thus, in the full-time four-wheel high-range drive mode, power transfer system 10 acts as an on-demand system for continuously monitoring and automatically regulating the actuated condition of transfer clutch 44 in a manner that is independent of any deliberate action by the vehicle operator. The magnitude of clutch actuation is defined between the limits of bi-directional sector rotation between its PT-H (i.e., fully-actuated) and FT-H (i.e., non-actuated) sector positions. Moreover, the magnitude of the clutch engagement force generated by lever arm 278 and applied to transfer clutch 44 is proportional to the magnitude of the output torque generated by rotary actuator 292 which, in turn, is proportional to the magnitude of the electrical control signal (i.e., percentage duty cycle) applied to rotary actuator 292. Thus, the amount of drive torque transferred across transfer clutch 44 is also proportional to the magnitude of the control signal.

Power transfer system 10 is also operable to permit transfer case 20 to be shifted out of either of the part-time and full-time four-wheel high-range drive modes and into a "Neutral" mode as well as into a full- time four-wheel low-range drive mode and a part-time four-wheel low-range drive mode. Specifically, upon mode select mechanism 56 signalling selection of the Neutral mode, rotary actuator 292 is actuated for causing sector plate 300 to rotate in the first direction for locating crowned roller 310 within fifth cam pathway 330 of mode slot 308 and range pin 320 within second cam pathway 324 of range slot 318. The contour of fifth cam pathway 330 is designed to retain crowned roller 310 in the (FT) position, whereby transfer clutch 44 is maintained in this non-actuated condition. However, range pin 320 is axially displaced due to the contour of second cam pathway 324 for shifting range sleeve 146 from its high- range (H) position into its Neutral (N) position.

When the full-time four-wheel low-range drive mode is selected, sector plate 300 is rotated in the first direction through the N sector position and into the FT-L sector position. Upon such movement, crowned roller 310 is guided in fifth cam pathway 330 of mode slot 308 for maintaining crowned roller 310 in the (FT) position while range pin 320 is guided within second cam pathway 324 to axial shift range sleeve 146 into its low-range (L) position. Thus, during "range" shifting of range sleeve 146 between its three distinct positions, sector plate 300 is configured to maintain transfer clutch 44 its non-actuated condition to eliminate the possibility of overloading. Preferably, "on-demand" operation in the full- time four-wheel low-range drive mode is similar to that disclosed above for operation in the full-time four-wheel high-range drive mode, wherein rotary actuator 292 is actuated in accordance with specific predefined relationships established based on the current value of the sensor input signals for rotatably driving sector plate 300 to a desired position between the limit of its FT-L and PT-L sector positions. Transfer clutch 44 is non- actuated when sector plate 300 is in its FT-L position and is fully-actuated when sector plate 300 is in its PT-L position. Accordingly, the modulation range is established between the limits of bi-directional sector rotation of sector plate between its FT-L and PT-L positions for causing movement of crowned roller 310 within sixth cam pathway 328 of mode slot 308 between the (FT) and (PT) position while range pin 320 is maintained in its (L) position due to the contour of third cam pathway 326.

Finally, transfer case 20 can be shifted into its part-time four- wheel low-range drive mode by causing sector plate 300 to be rotated to its PT-L position. In this position, crowned roller 310 is positioned in sixth cam pathway 332 in close proximity to its terminal end for locating crowned roller 310 in the (PT) position while range pin 320 is located in close proximity to the terminal end of third cam pathway for positioning range sleeve 146 in its low-range (L) position. Again, brake 334 can be thereafter shifted into its power-off condition for mechanically locking sector plate 300 in its PT-L sector position. While the above description detailed the movement of crowned roller 310 (and lever arm 276) and pin 320 (and range sleeve 146) upon rotation of sector plate 300 in a first direction, those skilled in the art will understand that actuator 292 is operable to rotate sector plate 300 in both directions to facilitate any desired shift between available modes. Moreover, while power transfer system 10 is disclosed to provide five different drive modes, in some applications it may be decided to limit the selection of available drive modes. For example, it is contemplated that mode select mechanism 56 could be easily adapted to permit selection of three drive modes, namely, the full-time four-wheel high-range drive mode, the Neutral mode, and the part-time four-wheel low-range drive mode. However, those skilled in the art will recognize that the above-described structure for sector plate 300 would still be applicable. With particular reference now to FIG. 6, a block diagram of a control system associated with power transfer system 10 is shown. Preferably, controller 50 is an electronic control module 340 having signal processing and information storage capabilities. In addition, first sensor group 48 is shown as a group of various "system" sensors that are provided for detecting and signaling specific dynamic and operational characteristics of the motor vehicle. The input signals generated by the "systems" sensors are delivered to electronic control module 340. Preferably, these sensors include a front speed sensor 342 for sensing the rotational speed (n_F) of front drive shaft 30, a rear speed sensor 344 for sensing the rotational speed (n_R) of rear drive shaft 40, a vehicle speed sensor 346 for sensing a vehicle speed (V), an ignition switch 348 for signalling the operational status of the vehicle, and a battery input 350 for poweπng electronic control module 340. In vehicles equipped with an anti- lock brake system (ABS), the original equipment ABS sensors provided at each wheel can be used for determining an "average" front drive shaft speed and rear drive shaft speed Alternatively, front and rear speed sensors 342 and 344, respectively, can be arranged for directly measuring the speed of front output shaft 32 and rear output shaft 42, respectively Moreover, it is possible for vehicle speed sensor 346 to be eliminated with the vehicle speed signal (V) being computed from the lower valued one of rotational speed signals (n_F) and (n_R) However, it is to be understood that any suitable speed sensing arrangement capable of generating a signal indicative of the rotational speed of a shaft is fairly within the scope of the present invention

The control system also utilizes various "operator-initiated" inputs, as generally categorized by second sensor group 54 These inputs include a brake sensor 352 for sensing when the vehicle operator is applying the brakes, a gear position sensor 354 for sensing a gear position of transmission 18, a steering angle sensor 356 for detecting the magnitude of a steering angle (φ), and an accelerator sensor 358 for sensing an accelerating condition of the vehicle Preferably, the accelerator sensor 358 is a throttle position sensor for sensing the degree of opening of a throttle valve associated with engine 16 or for sensing the degree of depression of an accelerator pedal and to produce a throttle position signal (A) The operator-initiated input signals are delivered to control module 340 where they are used, in conjunction with the system input signals

With reference now to FIG 7, a control sequence for the selection and the subsequent automatic control of the full-time drive modes is shown in a flow chart In general, flow chart represents a sequence of operations performed by electronic control module 340 which are diagrammatically shown in block form When mode select mechanism 56 signals selection of an available full-time mode, as indicated by block 360, a succession of control steps are repeated for determining the value of the control signal to be applied to electric rotary actuator 292 In the preferred form, the control signal is selected in accordance with various predefined relationships between the current value of a front and rear driveline speed differential (ΔN) and vehicle speed (V), as modified by current value of the steering angle (φ) and other operator-initiated inputs However, if any other mode is selected, then the control sequence jumps to a part-time routine, as indicated by block 362 Block 364 is representative of the control step in which the current value of the rotational speed of front drive shaft (n_F) and rear drive shaft (n_R) are read Block 366 indicates the step of reading the value of steering angle (φ) as detected by steering angle sensor 356 Block 368 represents the operation of selecting a control characteristic (C) in accordance with the steering angle (φ) FIG 9 illustrates a plot of an exemplary relationship, that may be stored as a look-up tabie or computed from an arithmetic equation, which correlates the control characteπstic (C) as a function of the detected steering angle

(φ) Next, block 370 represents the step of calculating the value of the speed differential (ΔN) according to the equation

ΔN=n_R-n_F+C Blocks 372 and 374 indicate the steps of reading the current value of the vehicle speed (V) as detected by vehicle speed sensor 346 and the throttle position (A) as detected by throttle position sensor As shown in block 376, control mode determines whether the vehicle speed (V) exceeds a predefined threshold value (V_τ) such as, for example, 5 mph If the vehicle speed is less than the threshold value (V_τ), a second determination is made (block ) 378 as to whether the value of the throttle position (A) exceeds a predefined threshold value (A_τ) such as for example, a 50% accelerator pedal depression angle If the vehicle speed (V) is less than its threshold value (V_τ) and the throttle position (A) exceeds its threshold value (A_τ), then the magnitude (i e , percentage of duty cycle) of the electric control signal is set as a preset value, such as

30% duty cycle, as indicated by block 380 In this manner, power transfer system 10 is adapted to transfer increased drive torque to front wheels 24 in response to quick acceleration at low vehicle speeds to inhibit anticipated wheel slip. However, if the value of the throttle position (A) is less than its threshold value (A_τ), then the magnitude of the duty cycle for the control signal is set in accordance with predefined relationships between the speed differential (ΔN) and vehicle speed (V), as indicated by block 382. Block 384 represents the step of outputting the electric control signal to actuator 292 for developing the desired amount of torque transfer, if any, across transfer clutch 44. As shown in block 386, a timer circuit actuated simultaneously with energization of actuator 292 for maintaining such energization for a predetermined time period (T) Once the period of energization (t) equals the predetermined time period (T), control module 340 repeats the control routine.

To enhance steering control, block 388 is indicative of the control step between steps 376 and 382 for determining whether the vehicle operator is applying the brakes when the vehicle speed (V) is greater than the threshold value (V_τ). Accordingly, if the vehicle operator is attempting to stop the vehicle, by applying the brakes (as sensed by brake sensor 352) during an occurrence of a low traction road condition and the vehicle speed (V) is greater than the predefined threshold (V_τ), then control module 340 sets the magnitude of the control signal sent to actuator 292 to zero (block 390) for de-actuating transfer clutch 44 This control sequence prevents simultaneous braking and torque-modulated four-wheel drive operation for providing the vehicle operator with greater steering and braking control. However, during the occurrence of a low traction condition when brake sensor 352 signals control module 340 that the vehicle operator is not applying the brakes, electronic control module 340 automatically energizes actuator 292 (block 384) for actuating transfer clutch 44 in accordance with the relationships generally denoted by block 382 With particular reference to FIG. 8, a set of exemplary plots used for establishing the magnitude of the duty cycle in response to the current value of the speed differential (ΔN) and the vehicle speed (V) during full-time operation, as diagrammatically referred to by block 360 in FIG. 7, will now be detailed. As seen, power transfer system 10 is programmed to correlate the percentage duty cycle of the electric control signal to a range of speed differential (ΔN) values. In general, the percentage duty cycle for the control signal increases from a minimum actuation value (Y%) to a maximum actuation value (100%) as the value of the speed differential (ΔN), within a particular vehicle speed range, increases from a minimum speed differential limit to a maximum speed differential limit (X). As such, when the value of the speed differential (ΔN) is less than the minimum speed differential limit, no drive torque is transferred through transfer clutch 44. However, when the value of the speed differential (ΔN) exceeds the minimum differential limit, a control signal is supplied to actuator 292 having a duty cycle value greater than (Y%). Thus, the minimum actuation duty cycle (Y%) for the control signal correlates to the point at which sufficient frictional engagement between the interleaved clutch plates results in the delivery of a portion of the total drive torque to slower turning output shaft of transfer case 20 for initiating "on-demand" limited slip control during a full-time four-wheel drive operation. Preferably, the portion of the total drive torque transferred through transfer clutch 44 to the slower turning output shaft increases as the magnitude of the duty cycle for the control signal increases from the minimum actuation value (Y%) to the maximum actuation value (100%). Preferably, the maximum value (X) of the speed differential (ΔN) correlates to the maximum actuation duty cycle (100%) at which point the maximum clutch engagement force is generated for completely locking-up transfer clutch 44. Part-time routine 362 is directed to controlling power transfer system 10 when the vehicle operator selects a operational mode via mode select mechanism 56 other than one of the full-time four-wheel drive modes, wherein control module 340 is adapted to supply a control signal to actuator 292 for rotating sector plate 300 to the particular sector position corresponding to the selected drive mode. Due to the use of bi-directional synchronized range shift mechanism 104, transfer case 20 can be shifted "on-the-fly" into any available drive mode without the requirement that the motor vehicle be in a non-motive condition. Preferably, the synchronizing capacity of synchronizer clutch apparatus 122 is selected to prevent high-range to low- range shifts when the vehicle speed exceeds a predetermined speed, most preferably in the range of about 30 to 50 miles per hour Alternatively, synchronizer clutch apparatus 122 can be equipped with a shift inhibitor mechanism for preventing such a high to low range shift above a certain vehicle speed. Commonly-owned U.S. Pat. No. 4,901 ,835 to Frost discloses one type of shift inhibitor applicable for use with the present invention. Such shift prevention can likewise be controlled electronically in association with the control system of the present invention. As will also be appreciated, any suitable type of synchronizer device (i.e., single-cone, dual-cone, multi-cone, strut-type, strutless, etc.) can be used with synchronized range shift mechanism 104.

With particular reference now to FIGS. 10 and 11 , an alternative construction for transfer case 20' is shown. In general, transfer case 20' can be installed in power transfer system 10 in substitution for transfer case 20. More particularly, transfer case 20' is similar to transfer case 20 with the exception that planetary gear assembly 68 has been replaced with a layshaft assembly 69. Thus, the above disclosure for controlling transfer clutch 44 in response to various sensor signals to modify the torque distribution across center differential 22 is again applicable As such, the control system diagrammed in FIG. 6, the control sequence of FIG. 7, and the plots of FIGS. 8 and 9 are applicable to control operation of transfer case 20'. As will be evident, like components are identified by like reference numerals.

Transfer case 20' is shown to include housing 58 formed by a series of modular sections which are suitably interconnected by a plurality of threaded fasteners 60. Input shaft 62 is shown rotatably supported in housing 58 via bearing assembly 64 Transmission output shaft, partially shown at 66, is coupled (i.e., splined) to input shaft 62 such that both are rotatably driven by engine 16 of the motor vehicle. A layshaft-type gear reduction unit, hereinafter layshaft assembly 69, is operably installed between input shaft 62 and a mainshaft 70. As will be detailed, layshaft assembly 69 is operable in a "high-range" drive mode for driving mainshaft 70 at a direct speed ratio (i.e., 1 :1 ) relative to input shaft 62. Layshaft assembly 69 is also operable in a "low-range" drive mode for driving mainshaft 70 at a reduced speed ratio (i.e., 0.37:1) relative to input shaft 62. Finally, layshaft assembly 69 is operable in a "Neutral" non- driven mode for interrupting the transfer of drive torque from input shaft 62 to mainshaft 70.

Layshaft assembly 69 includes a layshaft 73 rotatably supported from housing 58 via bearing assemblies 75 and 77 and having first and second gears 79 and 81 , respectively, formed thereon. Teeth 83 on first gear 79 are shown to be in constant meshed engagement with teeth 85 of a direct-drive gear 87 formed integrally with input shaft 62. Similarly, teeth 89 on second gear 81 are shown to be in constant meshed engagement with teeth 91 of a reduced-ratio gear 93 that is rotatably supported via bearing assembly 95 on mainshaft 70. The number of teeth associated with the two intermeshed gearsets are selected to cause reduced-ratio gear 93 to be driven at the desired reduced speed ratio relative to input shaft 62 and direct-drive gear 87. A bearing assembly 97 is shown to rotatably support a forward end portion of mainshaft 70 for rotation relative to input shaft 62. In addition, a first clutch plate 99 having peripheral clutch teeth 101 is shown to be fixedly secured (i.e., splined, pressfit, welded, etc.) to direct-drive gear 87 while a second clutch plate 103 having clutch teeth 105 is shown to be similarly fixed to reduced-ratio gear 92.

According to the present invention, a synchronized range shift mechanism 107 is provided in conjunction with layshaft assembly 69 and is operable for permitting transfer case 20' to be shifted "on-the-fly" between four-wheel high-range and low-range drive modes, in particular, synchronized range shift mechanism 107 includes a bi-directional synchronizer clutch apparatus 109 that is operable for selectively coupling mainshaft 70 to one of clutch plates 99 and 103 Synchronizer clutch apparatus 109 includes a hub 111 that is fixed (i.e., splined) to a radial flange segment 113 of mainshaft 70 and axial retained thereon via a pair of retaining rings 115. Hub 11 has an outer cylindrical nm 117 on which external longitudinal splines 119 are formed. Synchronizer clutch apparatus 109 also includes a plurality of struts (not shown), each being retained for longitudinal movement in one of a series of rcumferentially- spaced cutouts formed through outer cylindrical nm 117 of hub 110

Moreover, each strut is biased in a radially outward direction by an energizing spring. Synchronizer clutch apparatus 109 also includes range sleeve 146 having internal longitudinal splines 148 that mesh with external splines 119 on hub 111. Thus, range sleeve 146 is supported for rotation with and axial sliding movement on hub 111. Splines 148 include a central detent groove 150 that is provided for centering range sleeve 146 on humps 152 of the struts so as to define a centered Neutral position

FIG. 12 shows a sector plate 301 substantially similar to sector plate 300 of FIG. 5 with the exception that the cam segments of range slot 318 are arranged to reverse the "H" and "L" positions Thus, the same modes are available with transfer case 20' as were disclosed for transfer case 20.

Synchronizer clutch apparatus 109 further includes a first synchronizer assembly 133 for establishing speed synchronization between input shaft 62 and mainshaft 70 prior to permitting forward movement of range sleeve 148 to a high-range position whereat its splines 148 meshingly engage clutch teeth 101 of first clutch plate 99 for establishing a direct drive connection therebetween With range sleeve 148 positioned in its high-range position, the high-range drive mode is established between input shaft 62 and mainshaft 70 Similarly, a second synchronizer assembly 135 is provided for establishing speed synchronization between reduced-ratio gear 93 and mainshaft 70 prior to permitting range sleeve 146 to move rearwardly to a low-range position whereat its splines 148 meshingly engage clutch teeth 105 of second clutch plate 103 for establishing a reduced-ratio drive connection therebetween. With range sleeve 146 positioned in its low-range position, the low-range drive mode is established between input shaft 62 and mainshaft 70 Synchronizer assemblies 133 and 135 are shown as dual-cone arrangements similar to that shown in commonly-owned U.S. Pat. Nos. 5,085,303 and 5,335.087 to Frost. However, any synchronizer capable of permitting on-the-fly range shifting is considered an equivalent to that shown. With particular reference now to FIGS. 13 through 16, another preferred construction for a transfer case, identified by reference numeral 21 , will now be described. As with transfer case 20', transfer case 21 is adapted for use in power transfer system 10 in substitution for transfer case 20. Transfer case 21 is again shown to include housing 58 formed by a series of modular sections which are suitably interconnected by a plurality of threaded fasteners 60 Input shaft 62 is shown rotatably supported in housing 58 via bearing assembly 64 Transmission output shaft 66 is coupled (i.e., splined) to input shaft 62 such that both are rotatably driven by engine 16 of the motor vehicle. In addition, a dual- planetary gear reduction unit, hereinafter referred to as dual-planetary gear assembly 47, is installed between input shaft 62 and a mainshaft 70 and is operable, in conjunction with a range shift mechanism 45, for selectively establishing a direct speed ratio (i.e., high-range) and a reduced speed ratio (i.e., low-range) drive connection therebetween Thus, the "high- range" drive mode is established when mainshaft 70 is driven at the direct speed ratio (i.e , 1 :1) relative to input shaft 62 and the "low-range" drive mode is established when mainshaft 70 is driven at the reduced speed ratio (i.e., 0.50:1 ) relative to input shaft 62. Finally, dual-planetary gear assembly 47 is operable for establishing a "Neutral" non-driven mode for interrupting the transfer of drive torque from input shaft 62 to mainshaft 70

As best seen from FIG. 14, dual-planetary gear assembly 47 includes a first sun gear 177 integrally formed on input shaft 62, a second sun gear 179 rotatably supported on mainshaft 70, a set of full-length or first planet gears 181 each having teeth 183 meshed with teeth 185 of first sun gear 177, and a set of half-length or second planet gears 187 each having teeth 189 meshed with teeth 183 of one of first planet gears 181 and teeth 191 of second sun gear 179. Each full-length planet gear 181 is rotatably supported via bearings 193 on a pinion shaft 195, the opposite ends of which are mounted in front and rear carrier rings 197 and 199, respectively, of a carrier assembly 201. Similarly, each half-length planet gear 187 is rotatably supported via bearings 203 on a pinion shaft 205, the opposite ends of which are mounted in central and rear carrier rings 207 and 199, respectively, of carrier assembly 101. Preferably, carrier rings 197, 207, and 199 are secured together by suitable fasteners, such as bolts 209. Central carrier ring 207 is shown to be coupled via a splined connection 211 to mainshaft 70. To facilitate relative rotation between the various components of dual-planetary gear assembly 47, suitable thrust bearings 213 are shown positioned between the carrier rings and the sun gears.

According to the embodiment shown, first sun gear 177 has its gear teeth 185 located at a first radial distance from the principal axis, denoted by axis line "A", of mainshaft 70 while gear teeth 191 of second sun gear 179 are located at a second lesser radial distance relative to the principal axis. Each full-length planet gear 181 extends longitudinally substantially the full axial extent between front and rear carrier rings 197 and 199. Similarly, each half-length planet gear 187 extends longitudinally substantially the full axial extent between center and rear carrier rings 207 and 199. To provide the desired reduced speed ratio across dual- planetary gear assembly 47, first sun gear 177 has forty-three teeth, second sun gear 179 has thirty-eight teeth, full-length planet gears 181 have eighteen teeth, and half-length planet gears 187 have twenty-one teeth.

To provide means for selectively establishing the high-range and low-range drive connections between input shaft 62 and mainshaft 70. synchronized range shift mechanism 45 is provided in conjunction with dual-planetary gear assembly 47. As will be detailed, synchronized range shift mechanism 45 is operable for permitting transfer case 20 to be shifted "on-the-fly" between the four-wheel high-range and low-range drive modes As best seen from FIG. 14, synchronized range shift mechanism 45 includes a first synchronizer clutch apparatus 215 and a second synchronizer clutch apparatus 217 In general, first synchronizer clutch apparatus 215 is operable for establishing the high-range drive connection between input shaft 62 and mainshaft 70 by directly coupling carrier assembly 201 of dual-planetary gear reduction unit 47 to input shaft 62.

Since central carrier ring 207 is fixedly splined to mainshaft 70, direct coupling of carrier assembly 201 to input shaft 62 results in mainshaft 70 likewise being driven without reduction by input shaft 62. In contrast, second synchronizer clutch apparatus 217 is operable for establishing the low-range drive connection between input shaft 62 and mainshaft 70 by coupling second sun gear 179 to a central web plate 219 of housing 56 Such a coupling results in the braking of second sun gear 179 which, in turn, causes carrier assembly 201 to be rotatably driven at the desired reduced speed ratio relative to input shaft 62. First synchronizer clutch apparatus 215 is shown to include a hub 221 that is fixed via a splined connection 223 to input shaft 62, a first range sleeve 225 supported for rotation with and axial sliding movement on hub 221 , a first clutch plate 227 fixed (i.e., welded, etc.) to front carrier ring 197, and a cone-type synchronizer assembly 229 As best seen in FIG. 14, hub 221 has external longitudinal splines 231 formed on its outer peripheral nm and first range sleeve 225 has internal longitudinal splines 233 meshed therewith First range sleeve 225 is shown positioned in its neutral position, denoted by position line "N" Cone-type synchronizer assembly 229 is a dual-cone arrangement having an inner ring 235 fixed via a splined connection 237 to input shaft 62, an outer blocker ring 239 having blocker teeth 241 , and a reaction ring 243 having drive tangs 245 projecting into apertures 247 formed in clutch plate 227 As is otherwise conventional, the cone torque developed between the facing conicat surfaces of inner πng 235, blocker ring 239 and reaction ring 243 inhibits splines 233 of first range sleeve 225 from passing through blocker teeth 241 and into meshed engagement with clutch teeth 249 on clutch plate 227 until speed synchronization between carrier assembly 201 and input shaft 62 is complete Once speed synchronization is complete, first range sleeve 225 is free to move to its high-range position denoted by position line "H", whereat its splines 233 are coupled to clutch teeth 249 on clutch plate 227 for establishing the high-range dπve connection between input shaft 62 and mainshaft 70

The components of second synchronizer apparatus 217 are shown to be substantially similar to those of first synchronizer apparatus 215 and include a hub 251 fixed via a splined connection 253 to second sun gear 179, a second range sleeve 255 supported for rotation with and axial sliding movement on hub 251 , a second clutch plate 257 fixed to web plate 204 of housing 56, and a dual-cone synchronizer assembly 259 Second range sleeve 255 has internal longitudinal splines 261 that are meshed with external longitudinal splines 263 formed on the outer peripheral nm of hub 251 and is shown in its neutral position, denoted by position line "N" Dual-cone synchronizer assembly 259 includes an inner ring 265 fixed via splined connection 267 to second sun gear 179, a blocker ring 269 having blocking teeth 271 , and a reaction ring 273 having tangs 275 projecting into apertures 277 formed in second clutch plate 257 In operation dual-cone synchronizer assembly 259 inhibits splines 261 of second range sleeve 255 from passing through blocking teeth 271 of blocker ring 269 and into coupled engagement with clutch teeth 279 on second clutch plate 257 until speed synchronization between housing web plate 219 and second sun gear 179 is complete Obviously, such speed synchronization results in second sun gear 179 being braked and held stationary due to its direct coupling to housing 56 Upon completion of speed synchronization, second range sleeve 255 is permitted to move to its low-range position, denoted by position line "L", whereat its splines 261 are coupled to clutch teeth 279 of second clutch plate 259 for establishing the low-range drive connection between input shaft 62 and mainshaft 70 In addition to establishing the high-range and low-range drive modes, dual-planetary gear assembly 47 is also operable to establish a Neutral non-driven mode in which mainshaft 70 is not rotatably driven by input shaft 62 Thus, when it is desired to shift transfer case 20 into its Neutral mode, first and second range sleeves 225 and 255 are both moved to their respective neutral positions, whereat first range sleeve 225 is uncoupled from first clutch plate 227 and second range sleeve 255 is uncoupled from second clutch plate 257 As such, rotation of input shaft

62 and first sun gear 177 causes first and second planet gears 181 and 187 to rotate about their respective pinion shafts 195 and 205 which, in turn, causes second sun gear 179 to be rotatably driven As a result, carrier assembly 201 is not rotatably driven in response to rotation of first sun gear 177, whereby mainshaft 70 is also maintained in a non-driven state

Synchronized range shift mechanism 45 further includes a first range fork 281 having projections 283 that are retained in a groove 285 formed in first range sleeve 225, and a second range fork 287 having projections 289 retained in a groove 291 formed in second range sleeve

255 Transfer case 20 further includes means for causing coordinated axial movement of range forks 281 and 287 for establishing the three above-noted drive modes in response to actuation of a range actuator 43 Preferably, range actuator 43 is an electrically-actuated rotary device, such as an electric gearmotor and encoder assembly, which is operable for generating an output torque, the value of which vanes as a function of the magnitude of the electrical control signal applied thereto by controller 50

To provide means for controlling coordinated movement of range sleeves 225 and 255, a rotary output member 293 of range actuator 43 is secured to a first or "range" sector 295, that functions to change the output torque of range actuator 43 into an axially-directed force As best seen from FIGS 14 and 15, output member 293 is supported from transfer case housing 58 for rotation about an axis 297, and is secured in an aperture 299 formed in range sector 295. To generate the desire bi¬ directional axial movement of first range sleeve 225, range sector 295 includes a first guide slot 301 in which a first roller pin 303 is retained. First roller pin 303 is secured to first range fork 281. The contour of first guide slot 301 is configured to control the amount and direction of axial movement of first roller pin 303, first range fork 281 and first range sleeve 225 in response to the magnitude and direction of rotation of range sector 295. To generate the desired bi-directional axial movement of second range sleeve 255, range sector 295 includes a second guide slot 305 within which a second roller pin 307 is retained. Second roller pin 307 is operably secured to second range fork 287. Thus, the contour of second guide slot 305 is configured to control the desired amount and direction of axial movement of second roller pin 307, second range fork 287 and second range sleeve 255 in response to the magnitude and direction of rotation of range sector 295.

With particular reference now to FIG. 15, it can be seen that range sector 295 may be rotated by output member 293 to any one of three distinct sector positions, as labelled "Hi-Range", "Neutral", and "Lo- Range". The particular speed range established between input shaft 60 and mainshaft 70 across dual-planetary gear assembly 47 is controlled by the position of first and second roller pins 303 and 307 within first and second guide slots 301 and 305, respectively, which, as noted, also establishes the axial location of first and second range sleeves 225 and 255. In operation, the vehicle operator selects a desired operative drive mode via actuation of mode select mechanism 56, which, in turn, signals controller 50 of the selection. Thereafter, controller 50 generates an electrical control signal that is applied to range actuator 43 for controlling the rotated position of output member 293 and range sector 295. Range sector 295 is shown positioned in its Neutral sector whereat first roller pin

303 is centrally located in first guide slot 301 at the intersection of its first and second slot segments 309 and 311 to define its neutral (N) position and locate first range sleeve 225 in its neutral position Similarly, second roller pm 307 is centrally located in second guide slot 305 at the intersection of its first and second slot segments 313 and 315 to define its neutral (N) position and locate second range sleeve 255 in its neutral position. A spring-biased poppet assembly 317 is shown located in a central detent 319 for positively locating range sector 295 in its Neutral sector position When mode select mechanism 56 signals selection of a four-wheel high-range drive mode, controller 50 sends a control signal to range actuator 43 for causing range sector 295 to be rotated tn a first (i.e., counterclockwise) direction until poppet assembly 317 is located in a high- range detent 321 for locating range sector 295 in its Hi-Range sector position Such rotation of range sector 295 causes first roller pin 303 to travel in slot segment 309 of first guide slot 301 , the contour of which causes first roller pin 303 to move axial from the (N) position shown to the (H) position which, in turn, causes first range sleeve 225 to move from its neutral position to its high-range position. Concurrently, second roller pin 307 is guided within slot segment 315 of second guide slot 305 which is configured for maintaining second roller pin 307 in its (N) position which, in turn, maintains second range sleeve 255 in its neutral position. Finally, when mode select mechanism 56 signals selection of a four-wheel low- range drive mode, controller 50 sends an electrical control signal to range actuator 43 for causing range sector 295 to be rotated in a second (i.e., clockwise) direction until poppet assembly 317 is located in a low-range detent 329 for locating range sector 295 in its Lo-Range sector position. Such rotation of range sector 295 results in first roller pin 303 being guided within slot segment 311 of first guide slot 301 , the contour of which maintains first roller pin 303 in its (N) position which, in turn, maintains first range sleeve 225 in its neutral position. Concurrently second roller pin 307 is guided within slot segment 313 of second guide slot 307 the contour of which causes second roller pin 307 to move axially from its (N) position to the (L) position which, in turn, cause moving second range sleeve 255 to move from its neutral position to its low-range position Range sector 295 can be rotated directly from its Lo-Range sector position into its Hi-Range sector position as well as directly from its Hi-Range sector position into its Lo-Range sector position. Poppet assembly 317 preferably provides an electrical signal to controller 50 that is indicative of the rotated position of range sector 295.

Preferably, mode actuator 46 is also an electrically-actuated rotary actuator, such as an electric gearmotor and encoder assembly, which is operable for generating an output torque, the value of which varies as a function of the magnitude of the electrical control signal applied thereto by controller 50. To provide means for selectively controlling the magnitude of the clutch engagement force, a rotary output member 331 of mode actuator 46 is connected to a second or "mode" sector 333, for changing its output torque into an axially-directed force used for controlling the clutch engagement force applied by lever arm 278 on thrust mechanism 272 of transfer clutch 44. Output member 331 is supported from transfer case housing 58 for rotation about an axis 335 and is secured in an aperture 337 formed in mode sector 333. To generate the desired clutch engagement force, mode sector 333 includes a mode slot 339 within which a crowned roller 341 is retained. Crowned roller 341 is fixed to lever arm 278. The contour of mode slot 339 is configured to cause the desired direction and amount of pivotal movement of lever arm 278 in response to the direction and magnitude of rotation of mode sector 333 for generating the desired clutch engagement force to be exerted on thrust mechanism 272 of transfer clutch 44. Mode sector 333 may be rotated about axis 335 through a predefined range of angular motion defined between two distinct sector positions, labelled as "LOCKED" and "OPEN". With mode sector 333 in its LOCKED sector position, crowned roller 341 is positioned within mode slot 339 in close proximity to terminal end 343 thereof for establishing a part-time (PT) position. With crowned roller 341 in this (PT) position, lever arm 278 is pivoted toward transfer clutch 44 to its maximum extent so as to exert the maximum clutch engagement force on thrust mechanism 272 for frictionally compressing the interleaved clutch plates such that transfer clutch 44 is considered to be operating in its fully-actuated (i.e., locked-up) condition. In contrast, when mode sector 333 is rotated about axis 335 for locating it in its OPEN sector position shown, the contour of mode slot 339 has caused axial displacement of crowned roller 341 from the part-time

(PT) position into a full-time (FT) position. In this (FT) position, crowned roller 341 is located within mode slot 339 in close proximity to terminal end 345 thereof. Moreover, such movement of crowned roller 341 causes concurrent pivotal movement of lever arm 278 in a direction away from transfer clutch 44 which permits return spring 290 to axially shift thrust mechanism 272 so as to cause a proportional decrease in the clutch engagement force exerted on the interleaved clutch plates by thrust mechanism 272. Thus, once crowned roller 341 is in its (FT) position, lever arm 278 does not exert a clutch engagement force on thrust mechanism 272 and transfer clutch 44 is considered to be non-actuated, thereby permitting unrestricted speed differentiation across center differential 22.

As with the other embodiment, transfer case 21 is operable for establishing at least five distinct operative modes, namely, a part-time four-wheel high-range drive mode, a full-time four-wheel high-range drive mode, a Neutral mode, a full-time four-wheel low-range drive mode and a part-time four-wheel low-range drive mode. The particular operational mode selected is established by the position of crowned roller 341 in mode slot 339 and the position of roller pins 303 and 307 in guide slots 301 and 305. In operation, the vehicle operator selects a desired operative mode via mode select mechanism 56 which, in turn, signals controller 50 of the selection. Thereafter, controller 50 generates an electric control signal that is applied to range actuator 43 for controlling the rotated position of range sector 295. Likewise, controller 50 generates an electrical control signal that is applied to mode actuator 46 for controlling the rotated position of mode sector 333. As before, mode select mechanism 56 can take the form of any mode selector device which is under the control of the vehicle operator for generating a mode signal indicative of the specific mode selected

When mode select mechanism 56 signals that the vehicle operator has selected either of the part-time four-wheel high-range or low- range drive modes, controller 50 sends a control signal to mode actuator

46 for generating sufficient output torque to rotate mode sector 333 to its LOCKED sector position To provide means for holding mode sector 333 in its LOCKED sector position, power transfer system 10 includes brake 334 Brake 334 is an electrically-controlled spring-applied device that is operable in a "power-off' condition for braking inertial loads (i.e , rotation) of output member 331 of mode actuator 46 and, in turn mode sector 333 During controlled rotation of mode sector 333, an electrical signal from controller 50 maintains brake 334 in its "power-on" condition However, once mode sector 333 has been rotated to its LOCKED position, power to brake 334 is interrupted to shift it into its power-off condition, thereby locking output member 331 against rotation Depending on whether the part-time high-range or low-range drive mode is selected, range actuator 43 is sent an appropriate control signal from controller 50 for rotating range sector 295 to the corresponding one of its Hi-Range or Lo-Range sector positions

According to the present invention, when transfer case 21 is operating in either of the full-time four-wheel high-range or low-range drive modes, range sector 295 is rotated to the corresponding one of its Hi- Range and Lo-Range sector positions and mode sector 333 is initially rotated to its OPEN sector position Thereafter the electronically-controlled slip limiting/torque-biasing arrangement is activated for "on-demand" control of transfer clutch 44 Specifically, the actuated state of mode actuator 46 is continuously monitored and varied in accordance with specific predefined relationships established based on the current value of the sensor input signals Thus, in the full-time four-wheel drive modes, power transfer system 10 acts as an on-demand system for continuously monitoring and automatically regulating the actuated condition of transfer clutch 44 in a manner that is independent of any deliberate action by the vehicle operator. The magnitude of clutch actuation is defined between the limits of bi-directional rotation of mode sector 333 between its LOCKED (i.e., fully-actuated) and OPEN (i.e., non-actuated) sector positions. Moreover, the magnitude of the clutch engagement force generated by lever arm 278 and applied to transfer clutch 44 is proportional to the magnitude of the output torque generated by mode actuator 46 which, in turn, is proportional to the magnitude of the electrical control signal (i.e., percentage duty cycle) applied thereto. Thus, the amount of drive torque transferred across transfer clutch 46 is also proportional to the magnitude of the control signal Power transfer system 10 is also operable to permit transfer case 21 to be shifted out of the part-time and full-time four-wheel drive modes and into the "Neutral" mode. Specifically, upon mode select mechanism 56 signalling selection of the Neutral mode, mode actuator 46 is actuated for locating mode sector 333 in its OPEN sector position and range sector 295 is rotated by range actuator 43 to its Neutral sector position.

The foregoing discussion discloses and describes the preferred structure and controls presently contemplated for the present invention However, one skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined in the following claims.

Claims

1 A power transfer system for a four-wheel drive motor vehicle having a power source and front and rear drivelines, comprising a transfer case including a housing, an input shaft rotatably supported in said housing and driven by the power source, a front output shaft rotatably supported in said housing and coupled to the front driveline, a rear output shaft rotatably supported in said housing and coupled to the rear driveline, a mainshaft; a planetary gear assembly operable for selectively coupling said input shaft to said mainshaft to define a high- range drive mode whereat said mainshaft is driven at a direct speed ratio relative to said input shaft and a low-range dπve mode whereat said mainshaft is driven at a reduced speed ratio relative to said input shaft, said planetary gear assembly having a first member driven by said input shaft, a second member, and a third member driving said mainshaft and interconnecting said first member to said second member, a clutch apparatus including a range sleeve supported for rotation with said second member of said planetary gear assembly and movement between a first range position whereat said range sleeve couples said second member to said third member for establishing said high-range drive mode and a second range position whereat said range sleeve couples said second member to said housing for establishing said low-range drive mode, and synchronizer means for causing speed synchronization between said second member and said third member in response to movement of said range sleeve to said first range position, said synchronizer means further operable for causing speed synchronization between said second member and said housing in response to movement of said range sleeve to said second range position, an interaxle differential interconnecting said mainshaft to said front and rear output shafts for permitting speed differentiation therebetween, said interaxle differential including an input driven by said mainshaft, a first output interconnecting said input to said front output shaft, and a second output interconnecting said input to said rear output shaft, a transfer clutch operable for controlling speed differentiation across said interaxle differential, said transfer clutch including a set of first clutch plates supported for rotation with said first output of said interaxle differential, a set of second clutch plates supported for rotation with said second output of said interaxle differential and which are alternately interleaved with said first clutch plates, and a thrust mechanism movable between a first mode position whereat a minimum clutch engagement force is exerted on said clutch plates for permitting unrestricted speed differentiation between said front and rear output shafts, and a second mode position whereat a maximum clutch engagement force is exerted on said clutch plates for inhibiting speed differentiation; a drive mechanism interconnected to said range sleeve and said thrust mechanism for controlling coordinated movement thereof, said drive mechanism being movable between a FT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is located in said first mode position, a PT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is located in said second mode position, and a PT-L position whereat said range sleeve is located in said second range position and said thrust mechanism is located in said second mode position; and an actuator for selectively moving said drive mechanism; sensor means for detecting dynamic and operational characteristics of the motor vehicle and generating sensor input signals indicative thereof; a mode select mechanism for enabling a vehicle operator to select one of a full-time four-wheel high-range drive mode and a part-time four-wheel low-range drive mode and generating a mode signal indicative of the particular mode selected; and a controller for controlling actuation of said actuator in response to said mode signal and said sensor input signals, said controller operable for causing said actuator to move said drive mechanism between said FT-H and PT-H positions as a function of said sensor input signals when said mode signal indicates selection of said full-time four-wheel high- range dπve mode, and said controller operable for causing said actuator to move said drive mechanism to said PT-L position when said mode signal indicates selection of said part-time four-wheel low-range drive mode

2 The power transfer system of Claim 1 wherein said mode select mechanism is further operable for enabling the vehicle operator to select a part-time four-wheel high-range drive mode and generate a mode signal indicative thereof, said controller causing said actuator to move said drive mechanism to said PT-H position when said mode signal indicates selection of said part-time four-wheel high-range drive mode

3 The power transfer system of Claim 1 wherein said range sleeve is movable to a third range position whereat said second member of said planetary gear assembly is uncoupled from said third member and said housing for establishing a non-driven mode, wherein said drive mechanism is movable to a N position whereat said range sleeve is located in said third range position and said thrust mechanism is located in said first mode position, and wherein said mode select mechanism is operable for enabling the vehicle operator to select a neutral mode with a mode signal indicative thereof causing said controller to actuate said actuator for moving said drive mechanism to said N position

4 The power transfer system of Claim 1 wherein said transfer clutch is non-actuated when said thrust mechanism is in said first mode position and is fully-actuated when said thrust mechanism is in said second mode position, and wherein the actuated condition of said transfer clutch is continuously varied between said non-actuated and fully-actuated states in response to changes in the magnitude of said sensor input signals for automatically controlling speed differentiation across said interaxle differential

5 The power transfer system of Claim 1 wherein said first member of said planetary gear assembly is a sun gear, said second member is a πng gear, and said third member is a carrier assembly having pinion gears journally supported therefrom and which are meshed with said sun gear and said ring gear

6 The power transfer system of Claim 5 wherein said clutch apparatus includes a reaction member coupled for rotation with said ring gear, a brake plate fixed to said housing, a direct-drive hub supported for rotation with said mainshaft, a clutch hub fixed for rotation with said reaction member and on which said range sleeve is supported for rotation therewith and axial sliding movement thereon between said first and second range positions, and wherein said synchronizer means includes a first synchronizer assembly disposed between said clutch hub and said direct-drive hub for facilitating speed synchronization between said ring gear and said carrier assembly in response to movement of said range sleeve to said first range position whereat said range sleeve couples said clutch hub to said direct-drive hub, said synchronizer means further including a second synchronizer assembly operably disposed between said clutch hub and said brake plate for braking rotary movement of said ring gear in response to movement of said range sleeve to said second range position whereat said range sleeve couples said clutch hub to said brake plate

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7. The power transfer system of Claim 1 wherein said sensor means is operative for sensing the rotational speed of said front and rear output shafts and respectively generating front and rear speed signals indicative thereof, and further wherein said controller is operative for receiving said front and rear speed signals and generating a speed differential signal that is indicative of the speed differential between said first and second outputs of said interaxle differential, said controller operable for causing said actuator to move said drive mechanism toward said PT-H position in response to increasing values in said speed differential signal.

8. A transfer case for use in a four-wheel drive motor vehicle having a power source, front and rear drivelines, sensors for detecting dynamic characteristics of the motor vehicle, and an electronic controller for generating control signals in response to the sensor signals, said transfer case compπsing: a housing; an input shaft rotatably supported in said housing and driven by the power source; a front output shaft rotatably supported in said housing and coupled to the front driveline; a rear output shaft rotatably supported in said housing and coupled to the rear driveline; a mainshaft; a planetary gear assembly operable for selectively coupling said input shaft to said mainshaft to define a high-range drive mode whereat said mainshaft is driven at a direct speed ratio relative to said input shaft and a low-range drive mode whereat said mainshaft is driven at a reduced speed ratio relative to said input shaft, said planetary gear assembly having a sun gear driven by said input shaft, a ring gear, and a carrier assembly driving said mainshaft and having pinion gears journally supported tnerefrom that are meshed with said sun gear and ring gear; a clutch apparatus including a range sleeve supported for rotation with said ring gear and movement between a first range position whereat said range sleeve couples said ring gear to said carrier assembly for establishing said high-range drive mode and a second range position whereat said range sleeve couples said ring to said housing for establishing said low-range drive mode, and synchronizer means for causing speed synchronization between said ring gear and said carrier assembly in response to movement of said range sleeve to said first range position, said synchronizer means further operable for causing speed synchronization between said ring gear and said housing in response to movement of said range sleeve to said second range position; an interaxle differential interconnecting said mainshaft to said front and rear output shafts for permitting speed differentiation therebetween, said interaxle differential including an input driven by said mainshaft, a first output interconnecting said input to said front output shaft, and a second output interconnecting said input to said rear output shaft; a transfer clutch operable for controlling speed differentiation across said interaxle differential, said transfer clutch including a set of first clutch plates supported for rotation with said first output of said interaxle differential, a set of second clutch plates supported for rotation with said second output and alternately interleaved with said first clutch plates, and a thrust mechanism movable between a first mode position whereat a minimum clutch engagement force is generated and said transfer clutch is in a non-actuated state for permitting unrestricted speed differentiation between said front and rear output shafts, and a second mode position whereat a maximum clutch engagement force is generated and said transfer clutch is in a fully-actuated state for inhibiting speed differentiation; a drive mechanism interconnected to said range sleeve and said thrust mechanism for controlling coordinated movement thereof, said drive mechanism being movable between a FT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is located in said first mode position, a PT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is in said second mode position, and a PT-L position whereat said range sleeve is located in said second range position and said thrust mechanism is located in said second mode position, an actuator for selectively moving said drive mechanism, and a mode select mechanism for enabling a vehicle operator to select one of a full-time four-wheel high-range drive mode and a part-time four-wheel low-range drive mode and generating a mode signal indicative of the particular mode selected, whereby the controller actuates said actuator in response to said mode signal and the sensor signals, the controller being operable for causing said actuator to move said drive mechanism between said FT-H and PT-H positions as a function of the sensor signals when said full-time four-wheel high-range drive mode is selected for automatically controlling speed differentiation across said interaxle differential, and the controller being operable for causing said actuator to move said drive mechanism to said PT-L position when said part-time four-wheel low-range drive mode is selected

9 The transfer case of Claim 8 wherein said mode select mechanism is further operable for enabling the vehicle operator to select a part-time four-wheel high-range drive mode and generate a mode signal indicative thereof, the controller causing said actuator to move said drive mechanism to said PT-H position when said part-time four-wheel high- range drive mode is selected

10 The transfer case of Claim 8 wherein said range sleeve is movable to a third range position whereat said ring gear of said planetary gear assembly is uncoupled from said carrier assembly and said housing for establishing a non-driven mode, wherein said drive mechanism is movable to a N position whereat said range sleeve is located in said third range position and said thrust mechanism is located in one of said first and second mode positions, and wherein said mode select mechanism is operable for enabling the vehicle operator to select a neutral mode with a mode signal indicative thereof causing the controller to actuate said actuator for moving said drive mechanism to said N position

11 The transfer case of Claim 8 wherein the actuated condition of said transfer clutch is continuously varied between said non- actuated and fully-actuated states in proportion to changes in the magnitude of the sensor signals for automatically and continuously controlling speed differentiation across said interaxle differential

12. The transfer case of Claim 8 wherein said clutch apparatus includes a reaction member coupled for rotation with said ring gear, a brake plate fixed to said housing, a direct-drive hub supported for rotation with said mainshaft, a clutch hub fixed for rotation with said reaction member and on which said range sleeve is supported for rotation therewith and axial sliding movement thereon between said first and second range positions, and wherein said synchronizer means includes a first synchronizer assembly disposed between said clutch hub and said direct-drive hub for facilitating speed synchronization between said ring gear and said carrier assembly in response to movement of said range sleeve toward said first range position whereat said range sleeve couples said clutch hub to said direct-drive hub, said synchronizer means further including a second synchronizer assembly operably disposed between said clutch hub and said brake plate for braking rotary movement of said ring gear in response to movement of said range sleeve toward said second range position whereat said range sleeve couples said clutch hub to said brake plate

13. A power transfer system for a four-wheel drive motor vehicle having a power source and front and rear drivelines, comprising, a transfer case including a housing; an input shaft rotatably supported in said housing and driven by the power source; a front output shaft rotatably supported in said housing and coupled to the front driveline; a rear output shaft rotatably supported in said housing and coupled to the rear driveline; a mainshaft supported for rotation relative to said input shaft and said rear output shaft; a gear reduction unit operable for defining a high-range drive mode whereat said mainshaft is driven at a direct speed ratio relative to said input shaft and a low-range drive mode whereat said mainshaft is driven at a reduced speed ratio relative to said input shaft, said gear reduction unit including a layshaft rotatably supported in said housing and having first and second gears secured thereto, a direct-drive gear secured to said input shaft that is meshed with said first gear on said layshaft, and a reduced-ratio gear rotatably supported on said mainshaft that is meshed with and rotatably driven by said second gear on said layshaft; a clutch apparatus including a range sleeve supported for rotation with said mainshaft and movement between a first range position whereat said range sleeve couples said input shaft to said mainshaft for establishing said high-range drive mode and a second range position whereat said range sleeve couples said reduced-ratio gear to said mainshaft for establishing said low-range drive mode, and synchronizer means for causing speed synchronization between said input shaft and said mainshaft in response to movement of said range sleeve to said first range position, said synchronizer means further operable for causing speed synchronization between said mainshaft and said reduced-ratio gear in response to movement of said range sleeve to said second range position; an interaxle differential interconnecting said mainshaft to said front and rear output shafts for permitting speed differentiation therebetween, said interaxle differential including an input driven by said mainshaft, a first output interconnecting said input to said front output shaft, and a second output interconnecting said input to said rear output shaft a transfer clutch operable for controlling speed differentiation across said interaxle differential, said transfer clutch including a set of first clutch plates supported for rotation with said first output of said interaxle differential, a set of second clutch plates supported for rotation with said second output of said interaxle differential and which are alternately interleaved with said first clutch plates, and a thrust mechanism movable between a first mode position whereat a minimum clutch engagement force is exerted on said clutch plates for permitting unrestricted speed differentiation between said front and rear output shafts, and a second mode position whereat a maximum clutch engagement force is exerted on said clutch plates for inhibiting speed differentiation; a drive mechanism interconnected to said range sleeve and said thrust mechanism for controlling coordinated movement thereof, said drive mechanism being movable between a FT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is located in said first mode position, a PT-H position whereat said range sleeve is located in said first range position and said thrust mechanism is located in said second mode position, and a PT-L position whereat said range sleeve is located in said second range position and said thrust mechanism is located in said second mode position; and an actuator for selectively moving said drive mechanism, sensor means for detecting dynamic and operational characteristics of the motor vehicle and generating sensor input signals indicative thereof; a mode select mechanism for enabling a vehicle operator to select one of a full-time four-wheel high-range drive mode and a part-time four-wheel low-range drive mode and generating a mode signal indicative of the particular mode selected; and a controller for controlling actuation of said actuator in response to said mode signal and said sensor input signals, said controller causing said actuator to move said drive mechanism between said FT-H and PT-H positions as a function of said sensor input signals for automatically controlling speed differentiation across said interaxle differential when said mode signal indicates selection of said full-time four- wheel high-range drive mode, and said controller causing said actuator to move said drive mechanism to said PT-L position when said mode signal indicates selection of said part-time four-wheel low-range drive mode

14 The power transfer system of Claim 13 wherein said mode select mechanism is further operable for enabling the vehicle operator to select a part-time four-wheel high-range drive mode and generate a mode signal indicative thereof, said controller causing said actuator to move said drive mechanism to said PT-H position when said mode signal indicates selection of said part-time four-wheel high-range drive mode

15 The power transfer system of Claim 13 wherein said range sleeve is movable to a third range position whereat said mainshaft is uncoupled from said input shaft and said reduced-ratio gear for establishing a non-driven mode, wherein said drive mechanism is movable to a N position whereat said range sleeve is located in said third range position and said thrust mechanism is located in said first mode position, and wherein said mode select mechanism is operable for enabling the vehicle operator to select a neutral mode with a mode signal indicative thereof causing said controller to actuate said actuator for moving said drive mechanism to said N position

16 The power transfer system of Claim 13 wherein said transfer clutch is non-actuated when said thrust mechanism is in said first mode position and is fully-actuated when said thrust mechanism is in said second mode position, and wherein the actuated condition of said transfer clutch is continuously varied between said non-actuated and fully-actuated states in response to changes in the magnitude of said sensor input signals for automatically controlling speed differentiation across said interaxle differential

17. The power transfer system of Claim 13 wherein said clutch apparatus includes a first clutch plate fixed to said input shaft, a second clutch plate fixed to said reduced-ratio gear, and a clutch hub fixed for rotation with said mainshaft and on which said range sleeve is supported for rotation therewith and axial sliding movement thereon between said first and second range positions, and wherein said synchronizer means includes a first synchronizer assembly disposed between said clutch hub and said first clutch plate for facilitating speed synchronization between said input shaft and said mainshaft in response to movement of said range sleeve to said first range position whereat said range sleeve couples said clutch hub to said first clutch plate, said synchronizer means further including a second synchronizer assembly operably disposed between said clutch hub and said second clutch plate for causing speed synchronization between said mainshaft and said reduced-ratio gear in response to movement of said range sleeve to said second range position whereat said range sleeve couples said clutch hub to said second clutch plate.

18. The power transfer system of Claim 13 wherein said sensor means is operative for sensing the rotational speed of said front and rear output shafts and respectively generating front and rear speed signals indicative thereof, and further wherein said controller is operative for receiving said front and rear speed signals and generating a speed differential signal that is indicative of the speed differential between said first and second outputs of said interaxle differential, said controller operable for causing said actuator to move said drive mechanism toward said PT-H position in response to increasing values in said speed differential signal.

19. A power transfer system for a four-wheel drive motor vehicle having a power source and front and rear drivelines, comprising: a transfer case including a housing; an input shaft rotatably supported in said housing and driven by the power source; a front output shaft rotatably supported in said housing and coupled to the front driveline; a rear output shaft rotatably supported in said housing and coupled to the rear driveline: a mainshaft; a dual-planetary gear reduction unit operable for selectively coupling said input shaft to said mainshaft to define a high- range drive mode in which said mainshaft is driven at a direct speed ratio relative to said input shaft and a low-range drive mode in which said mainshaft is driven at a reduced speed ratio relative to said input shaft, said dual-planetary gear reduction unit having a first sun gear driven by said input shaft, a second sun gear, and a carrier assembly driving said mainshaft and having planet gears journally supported thereon intermeshed with said first and second sun gears; a first clutch apparatus including a first range sleeve supported for rotation with said input shaft and movement between a neutral position uncoupled from said carrier assembly and a high-range position coupling said input shaft to said carrier assembly, and first synchronizer means for causing speed synchronization between said input shaft and said carrier assembly in response to movement of said first range sleeve from its neutral position to its high- range position; a second clutch apparatus including a second range sleeve supported for rotation with said second sun gear of said dual-planetary gear reduction unit and movement between a neutral position uncoupled from said housing and a low-range position coupling said second sun gear to said housing, and second synchronizer means for causing speed synchronization between said second sun gear and said housing in response to movement of said second range sleeve from its neutral position to its low-range position; a drive mechanism interconnected to said first and second range sleeves for controlling coordinated movement thereof, said first drive mechanism being movable between a first range position whereat said first range sleeve is located in its high-range position and said second range sleeve is located in its neutral position, a second range position whereat said first and second range sleeves are each located in its neutral position, and a third range position whereat said first range sleeve is located in its neutral position and said second range sleeve is located in its low-range position; a range actuator for moving said first drive mechanism between said various range positions; an interaxle differential interconnecting said mainshaft to said front and rear output shafts for permitting speed differentiation therebetween, said interaxle differential including an input driven by said mainshaft, a first output interconnecting said input to said front output shaft, and a second output interconnecting said input to said rear output shaft; a transfer clutch operable for controlling speed differentiation across said interaxle differential, said transfer clutch including a set of first clutch plates supported for rotation with said first output of said interaxle differential, a set of second clutch plates supported for rotation with said second output of said interaxle differential and which are alternately interleaved with said first clutch plates; a thrust mechanism movable between a first mode position whereat a minimum clutch engagement force is exerted on said clutch plates for permitting unrestricted speed differentiation between said front and rear output shafts and a second mode position whereat a maximum clutch engagement force is exerted on said clutch plates for inhibiting speed differentiation; and a mode actuator for selectively moving said thrust mechanism; sensor means for detecting dynamic and operational characteristics of the motor vehicle and generating sensor input signals indicative thereof; a mode select mechanism for enabling a vehicle operator to select one of a full-time four-wheel high-range drive mode, a neutral mode, and a part-time four-wheel low-range drive mode, said mode select mechanism further operable for generating a mode signal indicative of the particular mode selected; and a controller for controlling actuation of said range and mode actuators in response to said mode signal and said sensor input signals, said controller causing said range actuator to move said drive mechanism to said first range position and modulate the position of said thrust mechanism between said first and second mode positions as a function of said sensor input signals when said mode signal indicates selection of said full-time four-wheel high-range drive mode, wherein said controller causes said range actuator to move said drive mechanism to said second range position when said mode signal indicates selection of said neutral mode, and wherein said controller causes said range actuator to move said drive mechanism to said third range position and said mode actuator to move said thrust mechanism to said second mode position when said mode signal indicates selection of said part-time four-wheel low-range drive mode

20 The power transfer system of Claim 19 wherein said mode select mechanism is further operable for enabling the vehicle operator to select a part-time four-wheel high-range drive mode and generate a mode signal indicative thereof, said controller causing said range actuator to move said drive mechanism to said first range position and said mode actuator to move said thrust mechanism to said second mode position when said part-time four-wheel high-range is selected

21 The power transfer system of Claim 19 wherein said transfer clutch is non-actuated when said thrust mechanism is in said first mode position and is fully-actuated when said thrust mechanism is in said second mode position, and wherein the actuated condition of said transfer clutch is continuously varied between said non-actuated and fully-actuated states in response to changes in the magnitude of said sensor input signals for automatically controlling speed differentiation across said interaxle differential during operation in said full-time four-wheel high-range drive mode -58-

22. The power transfer system of Claim 19 wherein said first clutch apparatus includes a first clutch plate fixed for rotation with said carrier assembly, a hub fixed for rotation with said input shaft and on which said first range sleeve is supported for rotation therewith and axial sliding movement thereon between its neutral and high-range positions, and wherein said first synchronizer means includes a first synchronizer assembly disposed between said hub and said first clutch plate for facilitating speed synchronization between said input shaft and said carrier assembly in response to movement of said first range sleeve toward its high-range position whereat said first range sleeve couples said hub to said carrier assembly and wherein said second clutch apparatus includes a second clutch plate fixed to said housing, a second hub fixed for rotation with said second sun gear and on which said second range sleeve is supported for rotation therewith and axial sliding movement thereon between its neutral and low-range positions, and wherein said second synchronizer means includes a second synchronizer assembly disposed between said second hub and said second clutch plate for braking rotary movement of said second sun gear in response to movement of said second range sleeve to said low-range position.

23. The power transfer system of Claim 19 wherein said sensor means is operative for sensing the rotational speed of said front and rear output shafts and respectively generating front and rear speed signals indicative thereof, and further wherein said controller is operative for receiving said front and rear speed signals and generating a speed differential signal that is indicative of the speed differential between said first and second outputs of said interaxle differential, said controller operable for causing said mode actuator to move said thrust mechanism toward said second mode position in response to increasing values in said speed differential signal.

24 A transfer case for use in a four-wheel drive motor vehicle having a power source and front and rear drivelines, comprising a housing, an input shaft rotatably supported in said housing and driven by the power source, a front output shaft rotatably supported in said housing and coupled to the front driveline, a rear output shaft rotatably supported in said housing and coupled to the rear driveline, a mainshaft, a dual-planetary gear reduction unit operable for selectively coupling said input shaft to said mainshaft to define a high-range drive mode in which said mainshaft is driven at a direct speed ratio relative to said input shaft and a low-range drive mode in which said mainshaft is driven at a reduced speed ratio relative to said input shaft, said dual- planetary gear reduction unit having a first sun gear driven by said input shaft, a second sun gear, and a carrier assembly driving said mainshaft and having planet gears journally supported thereon intermeshed with said first and second sun gears, a first clutch apparatus including a first range sleeve supported for rotation with said input shaft and movement between a neutral position uncoupled from said carrier assembly and a high-range position coupling said input shaft to said carrier assembly, and first synchronizer means for causing speed synchronization between said input shaft and said carrier assembly in response to movement of said first range sleeve from its neutral position to its high-range position, a second clutch apparatus including a second range sleeve supported for rotation with said second sun gear of said dual-planetary gear reduction unit and movement between a neutral position uncoupled from said housing and a low-range position coupling said second sun gear to said housing, and second synchronizer means for causing speed synchronization between said second sun gear and said housing in response to movement of said second range sleeve from its neutral position to its low-range position; a drive mechanism interconnected to said first and second range sleeves for controlling coordinated movement thereof, said first drive mechanism being movable between a first range position whereat said first range sleeve is located in its high-range position and said second range sleeve is located in its neutral position, a second range position whereat said first and second range sleeves are each located in its neutral position, and a third range position whereat said first range sleeve is located in its neutral position and said second range sleeve is located in its low-range position; a range actuator for moving said first drive mechanism between said various range positions; an interaxle differential interconnecting said mainshaft to said front and rear output shafts for permitting speed differentiation therebetween, said interaxle differential including an input driven by said mainshaft, a first output interconnecting said input to said front output shaft, and a second output interconnecting said input to said rear output shaft; a transfer clutch operable for controlling speed differentiation across said interaxle differential, said transfer clutch including a set of first clutch plates supported for rotation with said first output of said interaxle differential, a set of second clutch plates supported for rotation with said second output of said interaxle differential and which are alternately interleaved with said first clutch plates; a thrust mechanism movable between a first mode position whereat a minimum clutch engagement force is exerted on said clutch plates for permitting unrestricted speed differentiation between said front and rear output shafts and a second mode position whereat a maximum clutch engagement force is exerted on said clutch plates for inhibiting speed differentiation; a mode actuator for selectively moving said thrust mechanism; sensor means for detecting the rotational speed of said front and rear output shafts and generating front and rear speed signals indicative thereof; a mode select mechanism for enabling a vehicle operator to select one of a full-time four-wheel high-range drive mode, a neutral mode, and a part-time four-wheel low-range drive mode, said mode select mechanism further operable for generating a mode signal indicative of the particular mode selected; and a controller for controlling actuation of said range and mode actuators in response to said mode signal and said speed signals, said controller receiving said speed signals and generating a speed differential signal that is indicative of the speed difference between said front and rear output shafts, said controller causing said range actuator to move said drive mechanism to said first range position and modulate the position of said thrust mechanism between said first and second mode positions as a function of the magnitude of said speed differential signals when said mode signal indicates selection of said full-time four-wheel high-range drive mode, wherein said controller causes said range actuator to move said drive mechanism to said second range position when said mode signal indicates selection of said neutral mode, and wherein said controller causes said range actuator to move said drive mechanism to said third range position and said mode actuator to move said thrust mechanism to said second mode position when said mode signal indicates selection of said part-time four-wheel low-range drive mode.

25. The transfer case of Claim 24 wherein said mode select mechanism is further operable for enabling the vehicle operator to select a part-time four-wheel high-range drive mode and generate a mode signal indicative thereof, said controller causing said range actuator to move said drive mechanism to said first range position and said mode actuator to move said thrust mechanism to said second mode position when said part-time four-wheel high-range is selected.

26. The transfer case of Claim 24 wherein said first clutch apparatus includes a first clutch plate fixed for rotation with said carrier assembly, a hub fixed for rotation with said input shaft and on which said first range sleeve is supported for rotation therewith and axial sliding movement thereon between its neutral and high-range positions, and wherein said first synchronizer means includes a first synchronizer assembly disposed between said hub and said first clutch plate for facilitating speed synchronization between said input shaft and said carrier assembly in response to movement of said first range sleeve toward its high-range position whereat said first range sleeve couples said hub to said carrier assembly and wherein said second clutch apparatus includes a second clutch plate fixed to said housing, a second hub fixed for rotation with said second sun gear and on which said second range sleeve is supported for rotation therewith and axial sliding movement thereon between its neutral and low-range positions, and wherein said second synchronizer means includes a second synchronizer assembly disposed between said second hub and said second clutch plate for braking rotary movement of said second sun gear in response to movement of said second range sleeve to said low-range position.