Axle assembly with contaminant deflector

Abstract

An axle assembly includes a carrier housing having a deflector, a differential assembly, and an input shaft. The carrier housing has a main body and a pinion nose extending from the main body. The pinion shaft and the differential assembly are each rotatably supported by the carrier housing in driving engagement with one another. The pinion shaft extends through an aperture in the pinion nose. The deflector extends across at least a portion of an outer surface of the pinion nose to redirect contaminants from entering the carrier housing.

1 . An axle assembly comprising: 
 a housing having a main body and a nose portion extending from said main body;    a differential rotatably supported within said main body;    an input shaft extending through an aperture in said nose portion and driving said differential;    an annular seal positioned between said input shaft and said aperture in said nose portion; and    a deflector associated with an outer surface of said nose portion for directing foreign materials on said outer surface away from said seal.    
   
   
       2 . The axle assembly of  claim 1  wherein said deflector projects outwardly from said outer surface of said nose portion.  
   
   
       3 . The axle assembly of  claim 2  wherein said deflector is integrally formed with said nose portion of said housing.  
   
   
       4 . The axle assembly of  claim 2  wherein said deflector is secured to said outer surface of said nose portion.  
   
   
       5 . The axle assembly of  claim 2  wherein said nose portion of said housing includes a generally tubular wall member having said aperture formed in its end surface, and wherein said deflector is oriented to surround at least a portion of said outer surface of said tubular wall member.  
   
   
       6 . The axle assembly of  claim 5  wherein said deflector is oriented to completely surround said wall member.  
   
   
       7 . The axle assembly of  claim 1  wherein said deflector is recessed within said outer surface of said nose portion.  
   
   
       8 . The axle assembly of  claim 7  wherein said nose portion of said housing includes a generally tubular wall member having said aperture formed in its end surface and said deflector is defined as a groove formed in said outer surface which extends at least partially around said tubular wall member.  
   
   
       9 . The axle assembly of  claim 1  wherein said nose portion is angled relative to said main body to direct foreign material on said housing toward said deflector.  
   
   
       10 . The axle assembly of  claim 1  wherein said deflector varies in size between an upper portion of said nose portion and a lower portion thereof.  
   
   
       11 . The axle assembly of  claim 1  further comprising a first axleshaft driven by a first output member of said differential and a second axleshaft driven by a second output member of said differential, and wherein said differential includes an input member driven by said input shaft and a gearset operably disposed between said input member and said first and second output members.  
   
   
       12 . An axle assembly, comprising: 
 a carrier housing having a main body and a nose portion;    a differential rotatably supported within said main body;    an input shaft rotatably supported in said nose portion and operable for driving said differential;    an annular seal disposed between said input shaft and said nose portion; and    a deflector extending outwardly from said nose portion for diverting foreign material away from said seal.    
   
   
       13 . The axle assembly of  claim 12  wherein said deflector is integrally formed with said nose portion of said housing.  
   
   
       14 . The axle assembly of  claim 12  wherein said deflector is secured to an outer surface of said nose portion.  
   
   
       15 . The axle assembly of  claim 14  wherein said nose portion includes a generally tubular wall member having an aperture formed in its end surface, and wherein said deflector is oriented to surround at least a portion of said outer surface of said tubular wall member.  
   
   
       16 . The axle assembly of  claim 15  wherein said deflector is oriented to completely surround said wall member.  
   
   
       17 . The axle assembly of  claim 12  wherein said deflector varies in size between an upper portion of said nose portion and a lower portion thereof.  
   
   
       18 . An axle assembly, comprising: 
 a carrier housing having a main body and a nose portion;    a differential supported within said main body;    an input shaft supported in said nose portion and operable for driving said differential;    a seal disposed between said input shaft and said nose portion; and    a deflector formed as a groove in an outer surface of said nose portion for diverting foreign material away from said seal.    
   
   
       19 . The axle assembly of  claim 18  wherein said nose portion includes a generally tubular wall member having said aperture formed in its end surface through which said input shaft extends, and wherein said groove formed in said outer surface extends at least partially around said tubular wall member.  
   
   
       20 . The axle assembly of  claim 18  wherein said nose portion is angled relative to said main body to direct foreign material on said housing toward said deflector.  
   
   
       21 . The axle assembly of  claim 18  wherein said deflector varies in size between an upper portion of said nose portion and a lower portion thereof.  
   
   
       22 . An axle assembly, comprising: 
 a carrier housing having a main body portion and a generally tubular nose portion extending from said main body portion;    a differential unit rotatably supported in a central cavity defined within said main body portion;    an input shaft rotatably supported in a chamber defined within said nose portion and operable for driving said differential, said input shaft having an end portion extending through an aperture formed in an end surface of said nose portion;    an annular seal disposed between said end portion of said input shaft and said end surface of said nose portion; and    a deflector associated with an outer surface of said nose portion between said main body portion and said seal.    
   
   
       23 . The axle assembly of  claim 22  wherein said deflector projects outwardly from said outer surface of said nose portion.  
   
   
       24 . The axle assembly of  claim 23  wherein said deflector is integrally formed with said nose portion of said housing.  
   
   
       25 . The axle assembly of  claim 23  wherein said deflector is secured to said outer surface of said nose portion.  
   
   
       26 . The axle assembly of  claim 23  wherein said nose portion of said housing includes a generally tubular wall member having said aperture formed in its end surface, and wherein said deflector is oriented to surround at least a portion of said outer surface of said tubular wall member.  
   
   
       27 . The axle assembly of  claim 22  wherein said deflector is recessed within said outer surface of said nose portion.  
   
   
       28 . The axle assembly of  claim 22  wherein said deflector varies in size between an upper portion of said nose portion and a lower portion thereof.