Thrust washer construction for differential

Claim 1

A differential comprising: a housing having an internal surface defining a chamber; a drive gear secured to said housing externally thereof; a pair of side gears within said housing; a spider within said housing and between said side gears and extending into said housing at spaced locations on said internal surface; pinions journalled on and carried by said spider within said housing and engaged with said side gears; a noncircular recess in said internal surface adjacent at least one of said side gears and said pinions; and a noncircular thrust washer interposed between said internal surface and the one of said side gears and said pinions, said washer being sized and shaped to be snugly received within said recess and abut the sides thereof over a substantial distance to fix the washer against rotation; said recess having parallel sides and a flat bottom, said bottom being grooved immediately adjacent said sides, said washer having two parallel sides abutting said recess sides and overlying the adjacent groove, whereby said grooves permit said recess to be formed by broaching and thus eliminate the need for chamfering said washer.