Vehicle transfer case assembly with one-piece torque-transfer component having sprocket portion and output flange portion

1. A transfer case assembly for a vehicle, the transfer case assembly comprising:

a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received; and

wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another;

wherein the output flange portion has an inner surface defining an inner cavity;

wherein the output flange has a plurality of bosses extending radially inward at the inner surface into the inner cavity; and

wherein the bosses have axially-extending openings for receiving mounting features at the output flange portion.

2. The transfer case assembly of claim 1 , wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:

a bearing in the inner cavity interfacing with the sprocket portion at the inner annular surface.

3. The transfer case assembly of claim 1 , wherein the output flange portion has an outer surface, and further comprising:

an annular seal supported on the outer surface of the output flange portion.

4. The transfer case assembly of claim 1 , wherein the sprocket portion radially overlaps the plurality of bosses.

5. The transfer case assembly of claim 1 , wherein the one-piece torque-transfer component has an inner cavity extending axially through the sprocket portion and the output flange portion such that the one-piece torque-transfer component is hollow.

6. The transfer case assembly of claim 5 , wherein the one-piece torque-transfer component is powdered metal.

7. The transfer case assembly of claim 5 , further comprising:

a plate operatively connected to the one-piece torque-transfer component within the inner cavity; and wherein the plate closes the inner cavity.

8. The transfer case assembly of claim 1 , wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:

a transfer case housing radially surrounding the one-piece torque-transfer component;

a support post extending from the transfer case housing into the inner cavity;

a bearing supported on the support post in the inner cavity and interfacing with the sprocket portion at the inner annular surface such that the one-piece torque-transfer component is rotatably supported on the support post by the bearing.

9. The transfer case assembly of claim 8 , wherein the transfer case housing has an opening at which the output flange portion is positioned; wherein the output flange portion has an annular outer surface; and further comprising:

an annular seal supported on and surrounding the annular outer surface of the output flange portion at the opening.

10. The transfer case assembly of claim 8 , wherein the bearing is a first bearing; wherein the transfer case housing has an axially-extending flange; wherein the sprocket portion has a toothed outer surface; wherein the output flange portion has an axially-extending outer surface with a diameter less than a diameter of the toothed outer surface of the sprocket portion; and further comprising:

a second bearing supported on the annular outer surface of the output flange portion and the axially-extending flange of the transfer case housing such that the second bearing is positioned radially between the transfer case housing and the sprocket portion.

11. A transfer case assembly comprising:

a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received; wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another; wherein the sprocket portion has an annular inner surface defining an inner cavity;

a transfer case housing radially surrounding the one-piece torque-transfer component;

a support post extending from the transfer case housing into the inner cavity;

a bearing supported on the support post in the inner cavity and interfacing with the sprocket portion at the annular inner surface such that the one-piece torque-transfer component is rotatably supported on the support post by the bearing;

wherein the output flange portion has an annular outer surface; and

an annular seal supported on the annular outer surface of the output flange portion.

12. The transfer case assembly of claim 11 , wherein the transfer case housing has an opening and an axially-extending flange at the opening; wherein the output flange portion has an annular outer surface; and wherein the annular seal is supported on the axially-extending flange of the transfer case housing and surrounds the opening.

13. The transfer case assembly of claim 11 , wherein the one-piece torque-transfer component has an inner cavity extending axially through the sprocket portion and the output flange portion such that the one-piece torque-transfer component is hollow; and further comprising:

a plate operatively connected to the one-piece torque-transfer component within the inner cavity; and wherein the plate closes the inner cavity.

14. A transfer case assembly for a vehicle, the transfer case assembly comprising:

a one-piece torque-transfer component having a sprocket portion configured to receive torque and an output flange portion configured to transfer the torque received;

wherein the sprocket portion and the output flange portion rotate in unison about a common axis and are axially adjacent one another;

wherein the sprocket portion has an inner annular surface defining an inner cavity; and further comprising:

a bearing in the inner cavity interfacing with the sprocket portion at the inner annular surface.

15. The transfer case assembly of claim 14 , wherein the one-piece torque-transfer component is powdered metal.

16. The transfer case assembly of claim 14 , wherein the output flange portion has an outer surface, and further comprising:

an annular seal supported on the outer surface of the output flange portion.