Abstract: The invention is directed to a reduced-diameter brake rotor for heavy-duty vehicles. The rotor has a reduced diameter to enable it to be used in conjunction with reduced-diameter wheel end configurations. The rotor includes a radially-extending disc that in turn includes an inboard surface and an outboard surface, and a solid, constant cross-section between the inboard and outboard surfaces. The rotor also includes a radially-extending mounting flange for mounting the rotor to a wheel hub of the vehicle. An axially-extending sleeve is integrally formed with and extends between the disc and the mounting flange. The solid disc and other features of the rotor desirably reduce the peak temperature of the rotor by increasing its mass, reduce coning of the rotor during braking, and desirably maintain the heat transfer properties of the rotor while decreasing the brittleness and improving the hot strength of the rotor.

Abstract: A wheel end assembly for a heavy-duty vehicle includes an axle spindle and a hub rotatably mounted on the axle spindle. A main seal extends radially between the axle spindle and the hub. The seal includes a dynamic portion that seats in a bore formed in the wheel hub, and a static portion that seats on the axle spindle. The static portion includes a rigid carrier that in turn includes a first member, and a second member that is rigidly attached to the first member. An elastomer is bonded to the carrier member and forms a first external lip. The first external lip extends generally parallel to a chamfer formed in an inboard end of the hub. The first external lip, other external features, and internal features prevent contaminants from entering the wheel end assembly, retain lubricant in the assembly, and provide a dynamic expulsion surface to expel contaminants.

Abstract: Leaf springs, and methods of manufacturing thereof, having first and second sections, spaced apart along the length of said leaf spring, said sections are through hardened and tempered to achieve, respectively different levels of finished through hardness, are disclosed.

Abstract: A torque plate for heavy-duty vehicles includes a reduced size and structural features that enable the torque plate to be used in conjunction with a reduced diameter brake rotor. The torque plate is rigidly attached to an axle of the heavy-duty vehicle. The torque plate includes an axle ring that is formed with a thickness and an opening for receiving the axle, in which the axle ring engages an outer diameter of the axle. Each one of a pair of bodies is formed with a thickness and extends radially outwardly in opposite directions from the axle ring. Each body thickness is less than the axle ring thickness. Each one of a pair of carrier mounting bosses extends radially outwardly from a respective one of the bodies. The torque plate also includes a pair of anti-lock braking system sensor mounting bosses, and a pair of splash guard mounting bosses.

Abstract: Energy storing suspension components having an end configured to include an eye are disclosed in combinations with bushings for use in suspension systems for wheeled vehicles and trailers. The energy storing suspension components include an axle seat portion, an end, and a limb extending between the axle seat portion and the end. The limb includes a first taper wherein the limb decreases in width as the limb extends toward the end, a second taper wherein the limb decreases in thickness as the limb extends toward the end, wherein along the limb there is at least a portion where both the first taper and second taper are present, and a third taper that is further from the axle seat portion than the first taper and wherein the limb increases in width as the limb extends toward the end.

Abstract: A suspension system can include an air spring, an air reservoir external to the air spring, and a flow control device which variably restricts flow of air between the air spring and the air reservoir. Flow between the air spring and the air reservoir may be permitted in response to compliance of the suspension system, and the air spring can have an internal air volume at least 2½ times as great may permit flow between the air spring and the air reservoir in response to a predetermined pressure differential level across the flow control device. Multiple air reservoirs can be internal to an axle, or other suspension system or vehicle component, and can be isolated from each other.

Abstract: An air spring assembly including a damper that extends into an air cylinder float, the damper including a rod positioned having an end affixed to an end cap of the air cylinder float, a first piston affixed to the rod within the damper, a second piston affixed to the damper and having one or more seals on an outer surface thereof that sealingly engage an inner surface of the air cylinder float, wherein when a load applied to the air spring assembly is increased, the second piston and the second end of the damper move towards the end cap compressing air within the air cylinder float, wherein the air cylinder float is a solid member that does not expand as the air pressure within increases during compression, and wherein a protective membrane is positioned on an outer diameter of the air cylinder float.

Abstract: A hanger for axle/suspension systems of a heavy-duty vehicle includes an outboard wall spaced apart from an inboard wall. The outboard wall is connected to the inboard wall via a front wall. The outboard wall and the inboard wall are formed with an aligned opening extending through the outboard wall and the inboard wall. A top plate connected to the inboard wall, the outboard wall and the front wall. The top plate is formed with at least one circular opening or laterally oriented oblong-round opening and at least one laterally slotted opening. A fastener is disposed through the at least one circular opening or oblong-round opening. A second fastener is disposed through the at least one laterally slotted opening for mounting the hanger to a frame of the heavy-duty vehicle.

Abstract: An axle/suspension system for a heavy-duty vehicle with a pair of suspension assemblies which each are mounted on a hanger outboardly offset from the outboard surface of the vehicle main member from which it depends. Each suspension assembly includes a beam pivotally attached to the hanger outboardly offset from the outboard surface of the main member. The beam has a tapered profile including an upward outboard taper on at least the inboard side of the beam, which provides clearance between each beam and its respective vehicle main member during upward jounce travel or lifting of the axle/suspension system.

Abstract: Energy storing suspension components for use in suspension systems for wheeled vehicles and trailers, and suspension systems incorporating such energy storing suspension components are disclosed. The energy storing suspension components include an axle seat portion, a first end, and a first limb extending between the axle seat portion and the first end. The axle seat portion includes first and second surfaces with at least one of the first and second surfaces having at least two spaced apart recesses that are spaced from a center of the axle seat portion, the recesses being configured to receive respective protrusions extending from at least one suspension component that is connected to the energy storing suspension component when coupled within an axle coupling assembly.

Abstract: Liner assemblies for axle brackets of axle coupling assemblies are disclosed. The liner assemblies include a body having an elongated base and at least one extension member having a connector. Liner assembly and axle bracket combinations and method of connecting liner assemblies to axle brackets also are disclosed, with the liner assemblies including a body having an elongated base and at least one extension member having at least one connector, with the axle brackets including a body having a central portion and including at least one connector receiver configured to receive the at least one connector of the at least one extension member of the liner assemblies.

Abstract: A damping air spring and shock absorber combination for heavy-duty vehicle axle/suspension systems includes a damping air spring and a shock absorber both operatively attached to the axle/suspension system. The damping air spring primarily provides damping to the axle/suspension system over a first range of frequencies. The shock absorber primarily provides damping to the axle/suspension system over a second range of frequencies. The first range of frequencies is from about 0.0 Hz to about 6.0 Hz and the second range of frequencies is from about 0.0 Hz to about 13.0 Hz.

Abstract: An air spring with damping characteristics for a suspension assembly of a heavy-duty vehicle includes a bellows and a piston. The bellows includes a bellows chamber. The bellows is attached to a main member of the heavy-duty vehicle and to the piston. The piston includes an open bottom that is sealingly closed by a disc attached to the open bottom. The piston and the disc define a piston chamber. The piston is mounted on the suspension assembly of the heavy-duty vehicle. The bellows chamber and the piston chamber are in fluid communication with each other via at least one opening, wherein airflow between the bellows chamber and the piston chamber provides damping to the suspension assembly of the heavy-duty vehicle.

Abstract: A vehicle axle body is provided for incorporation into a vehicle axle. The vehicle axle body may be comprised of first and second axle body pieces. The first axle body piece may define at least a portion of a lower surface of the vehicle axle body and at least a portion of one of a front surface and a rear surface of the vehicle axle body. The second axle body piece is secured to the first axle body piece and may define at least a portion of an upper surface of the vehicle axle body and at least a portion of the other one of the front surface and the rear surface of the vehicle axle body. The thickness of the first and second axle body pieces may be different. Suspension component supports may be integrally formed with the upper and/or bottom surfaces of the axle body.

Abstract: Energy storing suspension components for use in suspension systems for wheeled vehicles and trailers are disclosed. The energy storing suspension components include an axle seat portion, an end, and a limb extending between the axle seat portion and the end. The limb includes a first taper wherein the limb decreases in width as the limb extends toward the end, a second taper wherein the limb decreases in thickness as the limb extends toward the end, wherein along the limb there is at least a portion where both the first taper and second taper are present, and a third taper that is further from the axle seat portion than the first taper and wherein the limb increases in width as the limb extends toward the end. Also disclosed are combinations of bushings and energy storing suspension components having an end configured to include an eye.

Abstract: A tie rod arm is provided for incorporation into a vehicle steering assembly. The tie rod arm has a grease cap portion with a steering knuckle connection formation and a grease seal cap. The steering knuckle connection formation is used to connect the tie rod arm to the body of a steering knuckle of the vehicle steering assembly. The grease seal cap receives the lower end of a kingpin of the vehicle steering assembly. The grease cap portion of the tie rod arm is integrally formed with an arm portion, which includes a tie rod connection formation to connect the tie rod arm to a tie rod of the vehicle steering assembly. A steering arm may also or alternatively be connected to the body of the steering knuckle and include an upper grease seal cap, which receives the upper end of the kingpin.