Abstract: A suspension system which includes at least one beam, a support spring extending between the vehicle frame and the support beam and a lift spring extending between a lift bracket welded to the beam and the vehicle frame. The support spring is precompressed by using a U-bolt and may be adjusted by increasing or decreasing the length of the U-bolt. Additionally, the spring provides a constant effective force throughout the entire path of travel of the tire-wheel assemblies attached to the axle. While the axle force provided by the spring increases, the force operates through a changing lever arm relative to the pivot point to assure that the spring force operating through the lever arm remains substantially constant throughout the path of travel of the suspension system.

Abstract: A vehicle suspension system having a central beam formed with a mounting flange on each side thereof. The beam is pivotally mounted to a suspension frame at one end, and rigidly attached to an axle at another end along substantially the entire length of the axle. A control arm is pivotally mounted to each mounting flange at one end, and to the suspension frame at another end whereby the pivot axis of the center beam and the control arms are axially aligned. Additionally, the pivot connection of the central beam provides one or two bushings which may have a constant spring rate, or which may include a spring rate which varies in the vertical and horizontal direction. In a second and third embodiment, a lift mechanism is provided for raising the axle from a ground engaging to a non-ground engaging position.

Abstract: A system for detecting a drowsy driver includes an axle with a sensor for measuring the movement of the axle and for producing an axle signal. The sensor typically measures any or all of the following: the lateral acceleration of the axle, the fore-aft acceleration of the axle, or the vehicle speed. A central processing unit compares the axle signal derived from the sensor measurements to a pre-determined drowsy threshold and an indicator indicates to the driver that drowsiness has been detected when the axle signal exceeds the pre-determined drowsy threshold.

Abstract: A mechanical face seal assembly has a cylindrical retainer fixedly mounted between a rotating shaft and a stationary housing. The rotating shaft defines a longitudinal axis and a rotating sealing ring rotates with the shaft. The rotating sealing ring is axially offset from the retainer. The retainer includes inner and outer legs which extend longitudinally along the axis and are radially spaced with respect to each other. The assembly also includes a non-rotating washer disposed within the retainer. A spring biases the washer towards the sealing ring. The invention also includes a method of easily assembling a seal by deforming an outer leg of the retainer after assembly of the seal components.

Abstract: A brake lining wear indicator is attached to a drum brake shoe backing plate adjacent the brake lining. The indicator provides a visual gage dimension that assists in the determination of when the brake linings should be replaced. This determination can be made in a very short period of time without requiring a physical measurement of the thickness of the brake lining on each brake shoe.

Abstract: A vehicle suspension system having a pair of hanger brackets. A first intermediate bracket dependent from a vehicle, a second intermediate bracket a pair of control arms, and a torque rod. One end of each control arm is pivotally mounted on a corresponding hanger bracket. Another end of each control arm, is pivotally attached to an axle seat. The torque arm is pivotally mounted between the first and second intermediate brackets. One end of a stabilizer bar is mounted to each control arm to increase the suspensions roll stability, and resistance to lateral deflection. In one embodiment, the stabilizer bar extends through a hole formed in each control arm, and in other embodiments, flanges extend outwardly from the stabilizer bar adjacent respective control arms for mounting the stabilizer bar to the control arms.

Abstract: An improved switch system is incorporated into a multi-speed transmission and engine combination. The switch system provides a positive electronic signal to an electronic control unit for the engine of both when the transmission is in a neutral state and when the transmission is in a gear-engaged state. In one embodiment, a switch plunger rides within a switch housing between two extreme positions. The switch plunger is at one axial position when the transmission is in neutral, and at the other axial position when the transmission is in a gear-engaged state. At either position, an electric circuit is completed and a signal is sent to an electronic control unit. The electronic control unit is thus provided with positive position feedback for the transmission.

Abstract: An improved mount for an electric motor and drive gear includes mounting both of the motor and drive gear within a gear housing for a vehicle wheel. The motor is mounted on one side of the drive axis of the wheel, and the drive gear is mounted in bearings on an opposed side of the drive axis. In this way, the overall longitudinal distance required for mounting both the motor and the drive gear is reduced when compared to the envelope of the vehicle wheel.

Abstract: A system for determining the weight of a vehicle includes a first axle subject to a relatively fixed axle weight. Typically, this axle is a front steering axle for a tractor-trailer combination vehicle. The load on this axle is considered known as the load does not vary significantly during the operation of the vehicle. A first accelerometer is supported on the first axle and measures the vertical acceleration of the first axle producing a first signal. Each additional axle on the vehicle, including any single rear or tandem drive axles and any trailer axles, also supports an accelerometer. The accelerometers on each of these additional axles measure the vertical acceleration of its respective axle. Each of these additional accelerometers produces a signal representative of its respective axle accelerations and these signals are combined to produce a second signal. A processor determines the vehicle weight by comparing the second signal to the first signal.

Abstract: A disc brake includes inventive backing plates. The backing plate includes tabs located at each end with a spring supported on a top edge of the backing plate between the tabs. The spring maintains the brake pad assemblies in proper orientation with respect to the disc and reduce the amount of noise created by the brake pad assembly components while the vehicle is in operation.

Abstract: An improved method for operating a engine, a transmission, and an associated electronic control module for the engine includes setting maximum torque levels for the engine by the electronic control module. The electronic control module determines the speed ratio of the transmission and sets a first relatively high torque load when it is determined that the transmission is in direct drive. If the electronic control module determines that the transmission is in non-direct drive then it sets a lower maximum torque load. The present invention has recognized that when in direct drive, the transmission may transmit higher torque loads than it would be able to do when it is in a gear reduction mode. In this way, the present invention increases the maximum torque rating for the transmission at its highest speed ratio.

Abstract: A sealing device for a drive line slip yoke includes a generally resilient seal and a substantially rigid cover that cooperate to provide a fluid-tight seal at the interface between a slip yoke and an axially moving splined shaft. The seal has a mounting portion that includes a shoulder received within a groove defined on an outer surface of the slip yoke. The cover is snapped over the seal and maintained in position by cooperating tabs on the cover and a groove defined on an outer surface of the seal. The seal includes a sealing portion having three axially spaced and radially inwardly extending lips. A middle lip acts as an O-ring that serves as a back-up in the event that one of the other two lips becomes damaged or deteriorates with use. The substantially rigid cover serves to maintain the seal in proper engagement with the end of the slip yoke and protects the seal from damage potentially caused by debris encountered during operation.

Abstract: An improved engine control provides rapid decrease in the output speed of the engine when an upshift of the transmission is being actuated. The system selectively actuates a speed retardation system to decrease the engine output speed to match a desired engine output speed at the next highest gear ratio. In one embodiment, an engine control actuates engine braking to achieve this rapid speed reduction. In other embodiments, an additional load may be placed on the engine, such as the actuation of a fan. An operator is preferably provided with a shift intent switch that provides an indication to the engine control that an upshift will be actuated. The engine control waits for an indication that the transmission has been moved to neutral. Once this indication is received, the speed retardation system is actuated to rapidly reduce the engine output speed toward a desired value.

Abstract: A universal joint bearing assembly incorporates a thrust washer molded from plastic. The plastic thrust washer eliminates the metal galling and metal debris that have been found in prior art universal joint bearings. A support notch is formed at radially outer surfaces to support an inner end of needle bearings. Resilient members bias the notch against the needle bearings such that the needle bearings are supported on the notch and against a seal at the outer end of the bearing cup. The resilient members are compressed when the universal joint is assembled such that the needle bearings operate properly. A central dome extension on the thrust washer insures that the thrust washer is not improperly mounted within the bearing cup. An outer face of the thrust washer is formed at an angle such that central portion extend further towards the trunnion than radially outer portions.

Abstract: An improved differential case is provided that resists rotation between the two differential case halves. Spline teeth extend from each of the mating faces of the two differential case halves into grooves in the other. The spline teeth and grooves prevent relative rotation. A method of making the differential case halves is also disclosed.

Abstract: An operator input control system assists shifting between gears in a multi-speed transmission without clutching. A single switch allows an operator to provide an indication of the next gear that is to be selected, and further allows the operator the option of requesting torque elimination when moving the transmission to neutral. In one embodiment, the switch includes a rotatable switch body that is held in either an upshift or downshift intent position. The operator is able to move the switch a slight additional rotational amount beyond the intent position to request torque elimination. Once the operator releases the switch, it returns to the upshift or downshift indicated position. The inventive switch reduces the complexity of operator input in an overall system for assisting an operator in shifting transmission speeds without clutching.

Abstract: A hydraulically actuated clutch includes a pair of hydraulic cylinder housings formed as blocks bolted to the clutch housing. In a most Preferred embodiment, the hydraulic cylinder housing extends into an opening in tie side wall of the outer clutch housing and is bolted at an outer location to the transmission bell housing. A fluid connection is made at an outer surface such that an assembler need not reach into the transmission bell housing to make the fluid connections. The hydraulic cylinder housing preferably has a machined piston bore, and fluid passages communicating the piston bore to the connection at the outer location on the hydraulic cylinder housing. In a second embodiment, a hydraulic cylinder housing also includes a block having a machined piston bore and fluid passage, however the block is bolted to an internal surface in the outer clutch housing.

Abstract: A shift by wire transmission system enables a driver to manually select a next desired gear and the system completes the shift automatically without requiring the driver to operate the clutch. The system includes an electronic transmission control unit that communicates with an electronic engine control unit to control engine speed during a shift in order to synchronize the speed of an engine shaft and the transmission shaft. The driver manually chooses a gear shift by moving a shift lever to thereby produce electrical signals indicative of the desired change in gears. Multiple or skip shifting is possible along with a method of automatically choosing a default gear in the event that the vehicle transmission is placed in neutral while the vehicle is in motion.

Abstract: A sealing device for a driveline slip yoke includes a flexible diaphragm and a generally rigid cap that cooperate to provide a fluid-tight seal across one end of the slip yoke. The diaphragm and the cap have outer peripheral edges that are preferably received within a groove on the slip yoke such that the cap maintains the diaphragm in proper sealing engagement with the slip yoke. The flexible diaphragm flexes and extends inwardly and outwardly of the slip yoke in response to varying pressures within the slip yoke caused by the relative axial movement of a splined shaft within the yoke. The cap not only maintains the diaphragm in proper sealing engagement with the slip yoke, but also limits the outward flexing of the diaphragm responsive to the pressure within the slip yoke. A slip yoke sealing device designed according to this invention is especially useful in applications that require that lubricant be maintained within the slip yoke over extensive periods during extensive use.

Abstract: A hydraulically actuated clutch includes a pair of hydraulic cylinders driving pistons to selectively move a clutch bearing to bring the clutch into and out of engagement. In standard clutches, a feature known as a clutch brake is sometimes contacted by the clutch bearing. The clutch bearing contacts the clutch brake to prevent rotation of the shaft under certain conditions. Because of this contact, the clutch bearing could rotate. Thus, anti-rotation structure is included in the inventive hydraulically actuated clutch. In a first embodiment, the anti-rotation structure includes surfaces formed on the sides of hydraulic cylinder housings which prevent rotation of the clutch bearing. The surfaces are preferably positioned radially inwardly from the pistons, and axially between the pistons and the clutch disks and plates which actually transmit the rotation through the clutch. In this way, the anti-rotation structure is optimally positioned to reliably prevent rotation.