Abstract: A process for connecting a non-symmetrical inside diameter vehicle spindle to a stationary housing is provided. Low and high stress areas of the spindle are determined, where correspondingly reduced and increased material cross sections are provided or increased cross sections are located in an orientation relative to a spindle axis. Consequently, the low and high stress areas of the spindle are aligned with corresponding areas of the stationary housing. Then, the spindle and stationary housing are connected by way of friction welding. This in turn results in selecting a section modulus of the connection of the spindle to the stationary housing, thereby achieving the lowest weight to strength ratio for the connection.

Abstract: An in-axle annular rotational speed sensor assembly (52) for drive axles (10) is provided which mounts directly to the drive axle differential bearing adjusters (36) in a relatively available and protected space (50) within the axle housing. The assembly utilizes the ferromagnetic adjuster to define a portion of the magnetic flux path (108) and maintains a large axial separation between the adjuster and the air gap (102) between the arrays of rotor and stator teeth (82, 100).

Abstract: An in-axle wheel speed sensor exciter rotor assembly (100) for sensing the rotational speeds of a drive axle ring gear (14/30) and a drive axle differential side gear (48) is provided. The assembly includes a tubular member (102) having teeth (110) for engagement with slots (112) provided on the side gear hub (48a) and carrying a first exciter rotor (116) at the opposite end (114) thereof. A second exciter rotor (118) is axially retained on the tubular member axially adjacent the first exciter rotor and is rotatable relative thereto. The second exciter rotor carries a coupling device (124/128) for engagement with threaded bores (126) provided in the drive axle ring gear/carrier assembly to rotationally couple the second exciter rotor to the ring gear and to axially retain the assembly (100) within the drive axle.

Abstract: A dual speed sensor pickup assembly (140) for sensing the rotational velocity of two independently rotatable, closely axially spaced exciter rotors (116 and 118) includes two pole piece assemblies (136 and 138) having axes skewed relative to one another, but radial relative to the common axes of rotation (24) of the exciter rotors. Applications include drive axles and antilock brakes.