Abstract: A method of machining a carrier housing for an axle assembly comprises obtaining a carrier housing including circumferentially spaced apart tabs and positioning a datum setting tool in engagement with the carrier housing. The carrier housing is clamped to a fixture to position the carrier housing at a first orientation relative to a coordinate system within a work cell. The datum setting tool is disengaged from the carrier housing. Portions of the carrier housing along a first side are machined to define features including a carrier mounting flange and a cylindrical bearing bore extending perpendicular to the carrier mounting flange while the carrier housing remains clamped at the first orientation. Different portions of the carrier housing, on a second opposite side of the carrier housing, are machined to define additional geometrical feature while the initial clamped orientation continues to be maintained.

Abstract: A modular tooling die for an axle housing includes a plurality of separable and coaxially aligned die sets. Each die set may include a cam driver that is engageable with first and second cam slide assemblies. The cam slide assemblies move toward one another along an axis that extends perpendicularly to an axis along which the cam driver translates. Multiple die sets are provided for possible use in a single press depending on the particular axle housing geometry to be manufactured. A wide variety of different geometrical configurations may be formed by simply replacing one or more die sets and inserting a differently sized or shaped blank within the press. A method of manufacturing various axle housings and the associated modular tooling is described.

Abstract: An assembly station for interconnecting a chassis and a body of a vehicle comprises a first carrier to support the chassis. A second carrier is suspended in a positive z-direction with respect to the first carrier and includes a plurality of spaced apart rests adapted to support the body prior to interconnecting the chassis and the body. A plurality of supports are coupled to the second carrier and spaced apart from the body when the body is supported on the rests. A portion of each of the supports is pivotable from a first position in a path of travel of the chassis to a second position outside of the path of travel of the chassis. The first carrier is moveable relative to the second carrier. The supports are adapted to engage the chassis and simultaneously support both the chassis and the body when the supports are in the first position.

Abstract: A vehicle axle assembly including an axle housing, carrier assembly, and first and second axle shafts. The axle housing is formed from an upper beam and a lower beam that are positioned in a clam-shell arrangement. The carrier assembly includes a carrier housing and a differential that includes a ring gear arranged in meshing engagement with a pinion. The first and second axle shafts extend outwardly from the differential in opposite directions. The pinion is rotatably supported by a self-lubricating cartridge pinion input bearing and the outboard ends of the first and second axle shafts are rotatably supported by self-lubricating and unitized grease wheel end bearings. These bearings do not require lubrication from oil contained inside the axle housing allowing for a reduced oil fill level in the axle housing, creating less viscous losses and better efficiency.

Abstract: A removable seat for a vehicle that includes a roll over protection system. The seat includes a seat bottom and a seat back assembly. The seat bottom adapted to be removably coupled to the vehicle. The seat back assembly is spaced apart from the seat bottom and adapted to be fixed by a bracket or removably coupled to first and second posts of the roll over protection system. The seat back assembly includes a seat back, a beam and saddles. The seat back is longitudinally oriented and parallel to a forward direction of vehicle travel. The beam includes a tube, a first bracket and a second bracket. The first bracket being fixed to a first end of the tube and the second bracket being fixed to a second end of the tube. The saddles fixing the tube to the seat back and includes a curved portion fixed to the tube.

Abstract: A steering column assembly includes a steering column housing, a tilt housing pivotally attached to the steering column, and a steering wheel shaft supported by the tilt housing. The tilt housing is moveable between a range of angular positions relative to the steering column housing. A tilt lever assembly, including a tilt lever that is moveable between a locked position and an unlocked position, mechanically actuates a tilt lock mechanism between an engaged condition and a disengaged condition. The tilt lever assembly has a tilt lever assembly center of mass that is positioned such that an inertial force acting in a forward direction on the tilt lever assembly center of mass urges the tilt lever towards the locked position.

Abstract: A cargo assembly is provided for use with a vehicle or trailer including a cargo area having a bed floor and a pair of sidewalls on opposite sides of the bed floor. The cargo area including an open end along an edge of the bed floor. A tailgate panel is disposed in the open end and includes first and second side edges having an upper connection mechanism and a lower connection mechanism that are each releasably and pivotally engaged with the pair of sidewalls.

Abstract: A vehicle axle assembly includes an axle housing and a carrier assembly. The carrier assembly includes a carrier housing and a differential assembly that includes a ring gear arranged in meshing engagement with a pinion gear. The gears are urged away from one another by separation forces during torque transfer. The carrier housing includes a curved wall circumscribed by a mounting flange as well as a plurality of integrally formed and parallel spaced apart gussets interconnecting the curved wall and the mounting flange. The gussets extend in a direction parallel to the gear separation forces to resist bending of the carrier housing. Other features increasing the structural rigidity of the one-piece carrier housing are discussed.

Abstract: A vehicle seat hinge assembly including a base plate, a seat support assembly, and an off-center hinge. The base plate is configured to mount to a vehicle and the seat support assembly is configured to mount to the seat. The off-center hinge of the vehicle seat hinge assembly is positioned at one corner of the base plate and pivotally couples at least part of the seat support assembly to the base plate. The base plate has a base plate centerline and the off-center hinge has a hinge axis that is arranged at an oblique angle relative to the base plate centerline.

Abstract: A suspension interconnection assembly comprises first and second saddle brackets and a fastener. Each saddle bracket comprises a base, a pair of arms spaced apart and have the base disposed therebetween, and a pair of shoulders. Each shoulder is disposed between the base and a respective arm. Each shoulder has a first beveled surface. The pair of shoulders cooperates with the base and the pair of arms to at least partially define a U-shaped pocket. The U-shaped pockets of each saddle bracket are sized to partially receive an axle housing. The fastener interconnects the saddle brackets to couple the saddle brackets and a spring to the axle housing. The beveled surfaces of each saddle bracket are adapted to operatively engage the peripheral wall. The pairs of arms of each saddle bracket are adapted to operatively engage one another after the beveled surfaces operatively engage the peripheral wall.

Abstract: A vehicle roll over protection system with at least one hoop member, longitudinal member, and connection device. The connection device couples the longitudinal member to the hoop member and includes first and second side plates that are fixedly attached on opposing sides of the hoop member in a substantially parallel arrangement to define a channel between the first and second side plates. Each side plate includes a cut-out that forms a cradle. The longitudinal member is received in the cradle. One or more wing plates are fixed to the longitudinal member. The wing plate(s) are received in the channel between the first and second side plates such that the first and second side plates act as displacement limiting features that limit the displacement of the longitudinal member relative to the hoop member in multiple directions.

Abstract: A heater duct can be coupled to an instrument panel of a vehicle, and comprises a base, a nozzle, and a neck. The base is sealingly coupled to the instrument panel and includes an inlet opening to receive air from a heater. The nozzle includes an outlet opening and is fluidly connected to the base. The nozzle deflects the air through the outlet opening and toward a predetermined region of a windshield. The neck extends between and is sealingly coupled to the base and nozzle. The base, nozzle, and neck cooperate to at least partially define an interior volume. The heater duct is positioned in an orthogonal coordinate system comprising an x-axis, a y-axis, and a z-axis. Air flowing from the inlet opening through the interior volume toward the outlet opening follows a path sequentially extending in substantially a negative z-direction, substantially a negative y-direction, and substantially a positive z-direction.

Abstract: A vehicle suspension assembly including a suspension control arm pivotally coupled to a vehicle frame member by a bushing assembly. The bushing assembly includes a bushing bracket, a bushing, and a cam adjustment mechanism that couples the bushing bracket to a connection interface of the vehicle frame member. The cam adjustment mechanism includes a cam plate rotatably retained on a first fastener such that the cam plate is rotatable relative to the bushing bracket independent of rotation of the first fastener. The cam plate is rotatable relative to the first fastener and the bushing bracket about an axis of rotation that is spaced from a centerline of the bushing at a nonparallel orientation. Rotation of the cam plate relative to the first fastener adjusts the position of the bushing bracket and therefore the bushing relative to the vehicle frame member to provide alignment adjustment.

Abstract: A method of interconnecting a vehicle chassis and body includes supporting the chassis on a first carrier and supporting the body on a second carrier suspended in a positive z-direction with respect to the first carrier; translating the first carrier in the positive z-direction; interconnecting the chassis and the body; and shifting supports coupled to the second carrier and spaced apart from the body from a first position in a path of travel of the chassis to a second position outside of the path by pivoting each support about a pivot axis. The method also includes shifting the supports from the second to the first position by pivoting each support about the pivot axis; translating the first carrier in a negative z-direction toward the supports; and supporting the interconnected chassis and body on the second carrier by engaging the chassis with the plurality of supports in the first position.

Abstract: A suspension interconnection assembly for a vehicle adapted to move along a surface of the ground includes an axle housing and a spring seat. The spring seat includes a pocket defined by a U-shaped saddle having a bottom wall that extends between a first leg and a second leg. The first and second legs include claw portions that are adapted to engage an upper portion of the axle housing. Welds secure the first and second claw portions to the axle housing so that areas of the axle housing adjacent the welds are in a state of residual tensile stress based on forming. The position of the welds provides a stress cancelling effect upon application of the load to the axle housing in a direction perpendicular to the surface of the ground.

Abstract: A vehicle suspension may include a crank bar and first and second lateral links. The crank bar is mounted to an axle assembly and is rotatable relative to the axle assembly about a first axis. The first lateral link may include a first end rotatably coupled to a first bracket fixed to a chassis of the vehicle and a second end coupled to the crank bar for rotation about a second rotational axis. The second lateral link may include a third end rotatably coupled to a second bracket fixed to the chassis and a fourth end coupled to the crank bar for rotation about a third rotational axis. A straight line having an infinite length may intersect the first rotational axis and one of the second and third rotational axes does not intersect the other of the second and third rotational axes.

Abstract: An accessory power center for a vehicle includes: a first terminal configured to be connected to a first reference potential of a battery of the vehicle; a second terminal configured to be connected to a second reference potential of the battery; and a fuse holder that includes: a first end that is electrically connected to the first terminal; and a second end. A first connector is configured to connect to a second connector of an accessory, the first connector including: a first electrical conductor that is electrically connected to the second end of the fuse holder; a second electrical conductor that is electrically connected to the second terminal; a third electrical conductor that is configured to receive power when backlights of the vehicle are powered; and a fourth electrical conductor that is configured to receive power when an ignition system of the vehicle is in an accessory state.

Abstract: A movable cargo rack assembly for installation on the cargo bed rails of a vehicle including a support assembly and a main arch that includes a leading edge, trailing edge, top segment, and side segments. The side segments extend downward from the top segment to body-side ends with insert portions that are received in stake holes in the cargo bed rails. The support assembly has two support arms with attachment ends that are pivotally connected to the cargo bed rails. The support assembly is pivotally connected to the main arch and is movable between a first configuration where the main arch is supported in two forward stake holes and the support arms extend out at an angle from the trailing edge and a second configuration where the main arch is supported in two rearward stake holes and the support arms extend out at an angle from the leading edge.

Abstract: A vehicle seat assembly for a vehicle having a cargo area bounded by a floor and at least one wall is provided along with a method of operation. The vehicle seat assembly comprises a seat back, a seat base, and a linkage assembly. The seat back of the vehicle seat assembly mounts to the wall and the linkage assembly mounts to the floor. The seat bottom is mounted to the linkage assembly and is moveable between stowed and deployed positions. When the seat bottom is in the deployed position, the seat bottom defines a deployed seat bottom plane. When the seat bottom is in the stowed position, the seat bottom is positioned below the deployed seat bottom plane. The seat bottom is separate from the seat back and is spaced apart from the seat back when the seat bottom is in the stowed position.

Abstract: An axle assembly includes a first rail assembly, a second rail assembly and an open-section twist beam connected to the first rail assembly and the second rail assembly. The twist beam includes an upper wall, a lower wall and rear wall wherein the upper wall and the lower wall are connected by the rear wall to define an open portion of the twist beam where the upper wall and the lower wall are separated by a vertical distance. The open portion of the twist beam is forward facing. The axle assembly further includes a torsion bar that extends through and is connected within the open portion of the twist beam.