Abstract: A module corner assembly wherein a wheel hub is permanently attached to a knuckle and various surfaces on the wheel hub and knuckle are machined in a same fixture utilized in holding the knuckle to deform an end on the wheel hub against a cone of a bearing. When a rotor is thereafter attached to the wheel hub it is also machined in the same fixture such that a perpendicular relationship is established between the axis of the wheel bearing and braking surfaces on the rotor and as a result a desired lateral run out relationship is achieved between the axis of the bearing and rotor surfaces.

Abstract: A process for manufacturing and assembling a corner assembly for a vehicle to achieve a perpendicular relationship between an axle of a vehicle and first and second braking surfaces on a rotor. In this process, after an inner race of a bearing is pressed onto a wheel hub and an outer race is pressed into a support structure to define a sub-assembly. The sub-assembly is placed onto a locating fixture such that the outer race supports the sub-assembly in a desired alignment where an out board surface on a radial flange is in a perpendicular relationship with the axis of the wheel hub. An arbor is inserted into an axle bore surrounding the axis of the wheel hub and the sub-assembly is rotated on the inner race to simulate operational condition of a vehicle as the surface of the out-board flange is finished machined to define a perpendicular relationship with the axis of the wheel hub.

Abstract: A corner module for use in a motor vehicle having a bearing pack through which a wheel hub for the motor vehicle is connected with a support member. The bearing pack includes an inner race and an outer race for retaining first and second roller elements such that a wheel attached to the hub may rotate with respect to the support member. The bearing pack is characterized by an exciter ring that is located between the first and second roller elements and the outer race is characterized by an opening that is in radial alignment with the exciter ring. A sensor that is fixed to the support member has a functional length and a sensing area that extends through the radial opening in the outer race and into the bearing pack to a position adjacent the exciter ring such that the functional length and sensing area is protected from exposure to contamination that may be present in the environment.