Power take-off unit with hydraulic disconnect

1. An all-wheel drive vehicle driveline comprising:

a housing assembly having a housing structure and a cover, the housing structure defining a first bore, which is disposed about a first axis, and a second bore that is disposed about a second axis that is not parallel to the first axis, the cover being removably mounted to the housing structure and defining first and second bearing mounts that are spaced apart along the first axis;

an input shaft that is adapted to be coupled to an input of a differential mechanism for common rotation about the first axis;

an intermediate shaft that is concentric with the input shaft, the intermediate shaft defining third and fourth bearing mounts that are spaced apart along the first axis;

first and second bearings, the first bearing being mounted to the first and third bearing mounts to support the intermediate shaft for rotation about the first axis relative to the cover, the second bearing being mounted to the second and fourth bearing mounts to support the intermediate shaft for rotation about the first axis relative to the cover, each of the first and second bearings being configured to transmit thrust loads in an associated direction along the first axis;

a third bearing disposed between the input shaft and the intermediate shaft, the third bearing comprising a plurality of cylindrical rollers;

a clutch having a first clutch member, which is coupled to the input shaft for rotation therewith, and a second clutch member that is coupled to the intermediate shaft for rotation therewith, the clutch being configured to selectively transmit rotary power between the input shaft and the intermediate shaft;

a bevel ring gear mounted to the intermediate shaft for rotation therewith;

a bevel pinion gear meshingly engaged to the bevel ring gear and rotatable about the second axis; and

an output shaft coupled to the bevel pinion for rotation therewith.

2. The all-wheel drive vehicle driveline of claim 1 , wherein the intermediate shaft is received into the input shaft.

3. The all-wheel drive vehicle driveline of claim 1 , wherein each of the first and second bearings has an inner bearing race and wherein one of the inner bearing races is abutted against the ring gear and the other one of the inner bearing races is abutted against a retaining ring that is mounted to the intermediate shaft.

4. The all-wheel drive vehicle driveline of claim 1 , wherein each of the first and second bearings has an outer bearing race and wherein one of the outer bearing races is abutted against the cover and the other one of the outer bearing races is abutted against a retaining ring that is mounted to the cover.

5. The all-wheel drive vehicle driveline of claim 1 , wherein the cover defines a pump mount and wherein the all-wheel drive vehicle driveline comprises a pump that is mounted to the cover.

6. The all-wheel drive vehicle driveline of claim 5 , wherein the housing assembly includes a lubricant for lubricating the first and second bearings and meshing of the bevel ring gear with the bevel pinion gear, and wherein the cover further defines a scraper that is configured to skim lubricant off the bevel ring gear as the bevel ring gear rotates.

7. The all-wheel drive vehicle driveline of claim 6 , wherein the cover defines a pump sump that is configured to direct a portion of the lubricant to an intake of the pump.

8. The all-wheel drive vehicle driveline of claim 1 , further comprising third and fourth bearings, wherein the housing assembly further comprises a pinion mount, wherein the third and fourth bearings support the output shaft for rotation relative to the pinion mount, and wherein the pinion mount is received into a bore formed in the housing structure and is fixedly coupled to the housing structure.

9. The all-wheel drive vehicle driveline of claim 1 , wherein the clutch comprises a first toothed element, which is coupled to the input shaft for rotation therewith, a second toothed element, which is coupled to the intermediate shaft for rotation therewith, and a collar that is slidable along the first axis into a position where it engages the first and second toothed elements.

10. The all-wheel drive vehicle driveline of claim 1 , wherein one of the first and second clutch members is axially movable along the first axis.

11. An all-wheel drive vehicle driveline comprising:

a housing assembly having a housing structure and a cover, the housing structure defining a first bore, which is disposed about a first axis, a second bore, which is disposed about a second axis that is not parallel to the first axis, and a first sump, the cover being removably mounted to the housing structure and defining a pump mount and a reservoir that is in fluid connection with the pump mount, the reservoir being defined by the cover and being disposed vertically at a level that is different from the first sump;

an input shaft that is adapted to be coupled to an input of a differential mechanism for common rotation about the first axis;

an intermediate shaft that is concentric with the input shaft;

a disconnect mechanism having a clutch and an actuator assembly, the clutch having a first clutch member, which is coupled to the input shaft for rotation therewith, and a second clutch member that is coupled to the intermediate shaft for rotation therewith, the clutch being configured to selectively transmit rotary power between the input shaft and the intermediate shaft, the actuator assembly having a piston that is configured to translate the first clutch member along the first axis between a first position and a second position;

a bevel ring gear mounted to the intermediate shaft for rotation therewith;

a bevel pinion gear meshingly engaged to the bevel ring gear and rotatable about the second axis;

an output shaft coupled to the bevel pinion for rotation therewith; and

a pump mounted to the pump mount, the pump having an inlet that is coupled in fluid connection to the reservoir in the cover, the pump being selectively operable for providing pressurized fluid to the piston of the actuator assembly.

12. The all-wheel drive vehicle driveline of claim 11 , further comprising first and second bearings, wherein the cover defines first and second bearing mounts that are spaced apart along the first axis, wherein the intermediate shaft defines third and fourth bearing mounts that are spaced apart along the first axis, wherein the first bearing is mounted to the first and third bearing mounts to support the intermediate shaft for rotation about the first axis relative to the cover, wherein the second bearing is mounted to the second and fourth bearing mounts to support the intermediate shaft for rotation about the first axis relative to the cover, each of the first and second bearings being configured to transmit thrust loads in an associated direction along the first axis.

13. The all-wheel drive vehicle driveline of claim 12 , wherein the housing assembly includes a lubricant for lubricating the first and second bearings and meshing of the bevel ring gear with the bevel pinion gear, and wherein the cover further defines a scraper that is configured to skim lubricant off the bevel ring gear as the bevel ring gear rotates.

14. The all-wheel drive vehicle driveline of claim 13 , wherein the scraper directs lubricant skimmed off of the bevel ring gear by the scraper is directed toward the reservoir.

15. The all-wheel drive vehicle driveline of claim 12 , further comprising a third bearing that is disposed between the input shaft and the intermediate shaft.

16. The all-wheel drive vehicle driveline of claim 15 , wherein the third bearing comprises a plurality of cylindrical rollers.

17. The all-wheel drive vehicle driveline of claim 11 , further comprising first and second bearings, wherein the housing assembly further comprises a pinion mount, wherein the first and second bearings support the output shaft for rotation relative to the pinion mount, and wherein the pinion mount is received into a bore formed in the housing structure and is fixedly coupled to the housing structure.

18. The all-wheel drive vehicle driveline of claim 11 , further comprising a first seal that sealingly engages the housing structure and the input shaft.

19. The all-wheel drive vehicle driveline of claim 18 , further comprising a second seal that sealingly engages the input shaft and the intermediate shaft.

20. The all-wheel drive vehicle driveline of claim 18 , further comprising a second seal that sealingly engages the cover and the intermediate shaft.