Abstract: This invention relates to a brake caliper adapted for use in a vehicle disc brake assembly and method and apparatus for producing the same. The method for producing the brake caliper comprises the steps of: (a) providing a mold member having at least two mold sections; (b) providing a core member having at least a first male extension which is adapted to form an integrally cast locating recess in the brake caliper which is used as a locating surface for subsequent machining of the brake caliper; (c) disposing the core member in the mold member in a predetermined position; (d) supplying a suitable material to the mold member so as to form a brake caliper within the mold; (e) removing the brake caliper from the mold, wherein the brake caliper includes an integrally cast locating recess formed therein by the first male extension of the core member; and (f) machining the brake caliper using at least the integrally cast locating recess formed therein as a locating surface.

Abstract: A brake pad assembly includes a brake pad including a base portion, a first ear portion, and an opposed second ear portion. The first ear portion and the second ear portion extend outwardly from the base section. The first ear portion includes a first upper section, a first central section, and a first lower section. The second ear portion includes a second upper section, a second central section, and a second lower section. A first clip receives the first ear portion and a second clip receives the second ear portion. The first ear portion includes a first defined contact location and a second defined contact location in relation to the first clip. The second ear portion includes a third defined contact location in relation to the second clip.

Abstract: A disc brake system comprising a brake piston with an annular groove defined in an outer side wall of said piston disposed to slide within a cylinder. A dust boot seal made of a flexible material having a first end and a second end, the first end engaging an outboard end of the cylinder, the second end engaging the annular groove. A plurality of flexible convolutions provided in the dust boot seal between the first and second ends, and the second end defining one or more slots.

Abstract: A drum-in-hat (DIH) disc brake assembly has a disc service brake, a DIH parking and emergency brake, and a parking brake anchor. A backing plate, an axle flange, and a caliper bracket each have at least two mounting apertures formed therethrough. The parking brake anchor includes a bracket portion having a pair of studs extending axially outwardly therefrom. The studs are structured and configured to extend through the respective mounting apertures of the backing plate, the axle flange, and the caliper bracket for securing the caliper bracket, parking brake anchor, and the backing plate to the axle flange.

Abstract: A brake pad assembly includes a brake pad including a base portion, a first ear portion, and an opposed second ear portion. The first ear portion and the second ear portion extend outwardly from the base section. The first ear portion includes a first upper section, a first central section, and a first lower section. The second ear portion includes a second upper section, a second central section, and a second lower section. A first clip receives the first ear portion and a second clip receives the second ear portion. The first ear portion includes a first defined contact location and a second defined contact location in relation to the first clip. The second ear portion includes a third defined contact location in relation to the second clip.

Abstract: This invention relates to a brake caliper adapted for use in a vehicle disc brake assembly and method and apparatus for producing the same. The method for producing the brake caliper comprises the steps of: (a) providing a mold member having at least two mold sections; (b) providing a core member having at least a first male extension which is adapted to form an integrally cast locating recess in the brake caliper which is used as a locating surface for subsequent machining of the brake caliper; (c) disposing the core member in the mold member in a predetermined position; (d) supplying a suitable material to the mold member so as to form a brake caliper within the mold; (e) removing the brake caliper from the mold, wherein the brake caliper includes an integrally cast locating recess formed therein by the first male extension of the core member; and (f) machining the brake caliper using at least the integrally cast locating recess formed therein as a locating surface.

Abstract: An opposed piston disc brake caliper adapted for use with a disc brake assembly includes a caliper of a one piece construction including an inboard leg and an outboard leg connected together by a bridge portion. The inboard leg has at least one piston bore formed therein, the outboard leg has at least one piston bore formed therein, the inboard leg has at least one generally axially extending opening formed therein which is coaxially aligned with the outboard leg piston bore, and the outboard leg has at least one generally axially extending opening formed therein which is coaxially aligned with the inboard leg piston bore.

Abstract: This invention relates to a brake caliper adapted for use in a vehicle disc brake assembly and method and apparatus for producing the same. The method for producing the brake caliper comprises the steps of: (a) providing a mold member having at least two mold sections; (b) providing a core member having at least a first male extension which is adapted to form an integrally cast locating recess in the brake caliper which is used as a locating surface for subsequent machining of the brake caliper; (c) disposing the core member in the mold member in a predetermined position; (d) supplying a suitable material to the mold member so as to form a brake caliper within the mold; (e) removing the brake caliper from the mold, wherein the brake caliper includes an integrally cast locating recess formed therein by the first male extension of the core member; and (f) machining the brake caliper using at least the integrally cast locating recess formed therein as a locating surface.