Abstract: A front suspension and steering mount cradle is disclosed for front-wheel-drive and all-wheel drive motor vehicles which provides improved component packaging, noise isolation, and heat shielding. The cradle includes laterally spaced apart supporting end arches integrally joined by a transversely extending inverted U-section saddle, wherein each arch is defined by an upper section terminating in downwardly diverging front and rear legs. Each front leg ends in a pivot pin fitting for connection to a suspension arm front pivot bushing while each rear leg terminates in a footpad housing connection for a rear bushing fitted on a rearward extending stem of each arm. Each cradle forward leg provides a pedestal bracket for supporting a frame front isolator assembly while each rear footpad supports a frame rear isolator assembly. A pair of upstanding engine mounting flanges on the saddle bight wall insure exact powertrain orientation.

Abstract: A method and system for detecting engine misfire in an internal combustion engine. A data signal containing a plurality of groups of data points generated from sampling crankshaft rotational displacement over three pre-determined angular sampling windows; is generated. Each of the plurality of groups of sampled data points represents a cylinder firing event. The data signal is conditioned, and the plurality of groups of sampled data points are, mapped into single misfire data points. The mapped single misfire detection points are then compared to a misfire detection dynamic threshold, and a misfire detection signal is output if the misfire detection points fall outside the dynamic threshold.

Abstract: An automatic transmission and transfer case operatively mounted in a four wheel drive vehicle controlled by a single selector lever that is moved to predetermined detented positions along a longitudinal gate to select the transmission drive ranges, reverse, neutral and park. A special pivot construction allows the selector lever to be moved laterally with respect to the normal longitudinal movement for transfer case gear ratio changes and neutral selection. A small lateral gate is employed to receive the selector lever located in alignment with the neutral detent position of the automatic transmission requiring the transmission to be in neutral when the transfer case is shifted. When moved into the lateral gate, the selector lever activates electronic controls effecting operation of a motor for shifting transfer case gear ratios and for selecting transfer case neutral.

Abstract: An independent suspension system for a vehicle driving axle is disclosed which includes a leading lower control arm which pivots about an axis which is nearly perpendicular to the upper control arm pivot axis and which is nearly perpendicular to the vehicle center line. By providing this perpendicular relationship between the pivot axes of the upper and lower control arms, an imaginary steering point results. This new imaginary steering point allows for improved vertical wheel travel, while minimizing the distance of half shaft plunge. By improving the vertical wheel travel and minimizing the distance of half shaft plunge, the ride of the vehicle is improved.

Abstract: A vehicle bumper includes a hollow tubular wall structure adapted to span the front or rear end of an automotive vehicle so as to absorb crash forces when the vehicle is involved in a crash situation at vehicle speeds above some predetermined speed level, e.g., five miles per hour. The hollow tubular wall structure includes an outer wall disposed to receive the crash force, an inner wall connectable to the vehicle, and four connector walls joining the outer wall to the inner wall. The four connector walls bend at a controlled rate to absorb crash energy. The outer and inner walls have aligned air openings adapted to conduct ram air to the vehicle radiator.

Abstract: A sealed edge joint can be formed between two metal panels such as an outer vehicle door panel and an inner door panel, by using a flowable sealant bead between the facing surfaces of the two panels, and a thin film of uncured paint-like resin between a flange on the outer panel and the exposed surface of the inner panel. The paint film is cured to a solid impervious condition by a baking operation performed on the completed door panel assembly.

Abstract: A front suspension and steering mount cradle is disclosed for front-wheel-drive and all-wheel drive motor vehicles which provides improved component packaging, noise isolation, and heat shielding. The cradle includes laterally spaced apart supporting end arches integrally joined by a transversely extending inverted U-section saddle, wherein each arch is defined by an upper section terminating in downwardly diverging front and rear legs. Each front leg ends in a pivot pin fitting for connection to a suspension arm front pivot bushing while each rear leg terminates in a footpad housing connection for a rear bushing fitted on a rearward extending stem of each arm. Each cradle forward leg provides a pedestal bracket for supporting a frame front isolator assembly while each rear footpad supports a frame rear isolator assembly. A pair of upstanding engine mounting flanges on the saddle bight wall insure exact powertrain orientation.

Abstract: An apparatus and method for controlling low engine idle RPM without discharging a vehicle battery by monitoring the vehicle alternator field modulation. The apparatus includes an engine control module, an alternator, electrical loads and a switch module. The engine control module includes a first input and a first output forming a portion of a first feedback loop. The first input and first output enable the engine control module to sense and control the idle RPM of the engine. The alternator includes an armature and a field coil where rotation of the armature and modulation of the field coil controls the amount of current supplied by the alternator. The switch module modulates the field coil upon receipt of a drive signal from the engine control module.

Abstract: A speed sensor assembly is mounted to a steering knuckle with a threaded fastener. The fastener is initially hand tightened until it is axially obstructed by a spacer provided on the speed sensor assembly. A tool then is used to apply high torque to the fastener so as to deflect or break away the spacer so that the speed sensor assembly may be tightly clamped to the steering knuckle by the fastener. The spacer prevents hand tightened speed sensor assemblies from being properly aligned with a tone wheel. Unless a tool is used to fully seat the speed sensor assembly, the assembly will give a false test signal indicative of improper or incomplete mounting.

Abstract: An electro-mechanical clutch actuator is provided for disengaging a clutch of a transmission. The clutch actuator includes an assist spring for reducing the amount of motor torque required for operating the clutch actuator. The clutch actuator also includes a self adjustment feature which accommodates for clutch disk wear.

Abstract: A method of power management for a hybrid powertrain system includes the step of determining a storage power from a power flow into or out of an energy storage apparatus. The method also includes the step of determining an actual level of energy stored in the energy storage apparatus, determining a desired level of energy stored in the energy storage apparatus, and determining an energy storage level error from a difference between the desired level of energy stored and the actual level of energy stored. The method further includes the step of determining an engine power change from the energy storage level error and an actual storage power flow, determining an engine power setting from the engine power change, and modifying the engine by the engine power setting.

Abstract: A door-ajar switch assembly for a door movable between open and closed positions relative to an opening in a vehicle body. The switch includes a housing supported adjacent to the opening in a position of inward and outward adjustment. An actuator projects outwardly from the housing and is retractable inwardly to a switch-actuating position. A switch operator is mounted on the door and moves the switch-actuator to the switch-actuating position when the door is closed. The switch operator has an actuator-engaging front face. An adjustment member is secured to the front face of the operator to engage the actuator when the door is initially closed to retract the actuator beyond the switch-actuating position and push the housing inwardly to an adjusted position.

Abstract: A one-piece blow molded bumper end cap is provided for use in combination with a vehicle bumper assembly. The bumper end cap functions as an end plug to enhance air flow into the engine compartment when used in combination with a flow-through bumper. The bumper end cap also includes structural features which improve the crashworthiness of the bumper system in lower speed corner impacts, as well as, higher speed frontal impacts.

Abstract: A bearing removal tool and method of removing a bearing assembly for the wheel hub is provided. The bearing removal tool includes an elongated bar having a fixed end portion and a free end portion which is offset from the fixed end portion, and a cup which is adapted to engage the outer race of a bearing assembly without interfering with other components, such as a tone wheel, associated with the bearing assembly. A driving member is operably coupled between the elongated bar and the cup to urge the cup away from the elongated bar, thereby removing the bearing assembly from the wheel hub.

Abstract: A universal slider bushing includes an inner body within an outer body. The inner body has a convex spherical segment. The outer body has a concave spherical segment or socket supporting the convex spherical segment for universal movement. The inner body has a central through-passage. A ball bearing supports a shaft in the passage for longitudinal sliding movement and for rotation about its longitudinal axis.

Abstract: A filling aid for field filling the engine cooling system of automotive vehicles with cooling liquids. For field service, the filling aid is mounted in a stabilized upright orientation by an integral fluid sealing connection to a filler neck of the deareation chamber of a coolant bottle of the system so that it extends above the bottle. Coolant is added into the cooling system through the filling aid until the filling aid and deareation chamber are filled with coolant. Because a taller column of coolant has been established by use of the filling aid, potential energy is increased and coolant is quickly fed by increased pressure and force into the engine cooling system. When sufficient coolant fills the system, any coolant left in the filling aid may be released by removing a closure clamp previously installed on an overflow tube leading from the deareation chamber so that it drains with no spills from the filling aid to an overflow chamber of the coolant bottle.

Abstract: An antenna apparatus includes electrical contacts which each have a sliding mast contact portion and a docking contact portion. The apparatus includes a linearly extendable and retractable one-piece mast antenna. The sliding mast contact portions of the electrical connectors make contact with an outer surface of the mast antenna along the full length of the antenna as it is extended and retracted. The docking contact portions of each electrical connector make electrical contact only with a lower end portion of the antenna which has a larger diameter than the remainder of the antenna. The docking contact portions of each electrical connector only make electrical contact with the lower end portion when the antenna is substantially completely extended. In this manner the docking contact portions experience only a small degree of the wear experienced by the sliding mast contact portions, which make contact with the outer surface of the antenna along almost its entire length.

Abstract: A top system includes a hard top which may be operatively installed over a folded soft top. The top system allows delivery of both the hard top and the soft top to the customer. Additionally, the top system allows for an expanded range of uses of the associated motor vehicle. The owner/user can have the hard top on for greater comfort and less noise on long trips and on arrival, take the hard top off and have the soft top for local use with the benefit of open air driving. The soft top is ready to be moved to its operative position or retained in the stored position for available protection from the element from adverse weather conditions. The ability of the top system to allow the hard top to be operatively installed over the folded soft top is made possible largely in part due to the several unique aspects. For example, the soft top folds back and is contained within the boundaries of the body side of the motor vehicle and the tailgate area while having a low stack height.

Abstract: The present invention provides an electrical adaptor for transmitting current from a standard seven prong trailer plug power source to a female cigarette lighter plug. The adaptor uses two of the seven prongs of the seven prong trailer plug power source to supply current to the female cigarette lighter plug. The electrical adaptor provides a way of using a standard trailer plug, normally located external to a vehicle, to supply electrical current to an accessory. The adaptor is contained within a cylindrical plastic housing. A thermal insulator is positioned around the female cigarette lighter plug to thermally insulate it from the cylindrical plastic housing.

Abstract: An automotive vehicle body has a side opening that is opened and closed by a sliding door. The door is operated with a power drive mechanism that is pivotally mounted thereon and extends through the side opening. The power drive mechanism includes a reversible electric motor driven friction drive wheel and is spring biased to forcibly engage this wheel with a drive/guide track that is located beneath the vehicle floor and attached to the vehicle body. The friction drive wheel rides on the drive/guide track to open and close the door and also helps guide and stabilize its sliding movement. The spring load on the friction drive wheel is limited so as to provide sliding door operation with the motor under normal conditions and allow slippage at the friction drive wheel to cease door movement when the door encounters a physical object in the door opening.