Abstract: A method of forming an axle assembly having a hollow member. A hollow member such as a cylindrical tube is formed into a polygonal cross-section having an end portion. Bulkheads maybe located into the hollow member prior or after the polygonal forming step to improve proximate strength and transfer suspension bending moments. The end portions are formed to receive a preformed king pin boss having an end portion of approximately the same size as the frustoconical end. The members are welding together and the king pin and hollow member are bent to a desired axle shape. In another method sequence, the kingpin boss is directly formed into the end of the hollow member.

Abstract: An automatic axle engagement system utilizes wheel speed sensors, engine control, and braking control to provide optimal engagement of a front drive axle to provide all wheel drive under poor driving conditions. The system includes a transfer case that is coupled to a power source and which has output shafts for front and rear drive axles. The engine provides torque to the transfer case via an input shaft. Wheel sensors generate wheel speed signals that are transmitted to a controller, which determined whether or not there is wheel slip. The controller initiates a shift to drivingly engage the front drive axle if there is wheel slippage by controlling one or both of the output torque or axle braking forces to bring rotational speeds of the input shaft and the rear axle output shaft within a predetermined speed range.

Abstract: A wheel end assembly includes an output shaft that is directly mountable to a wheel adapter to drive a vehicle wheel. A gear assembly is coupled to the output shaft to transfer driving force from an input to the output shaft. The gear assembly includes an output gear that is directly coupled to the output shaft. Thus, the wheel adapter and output gear are both supported directly on the output shaft. The gear assembly and output shaft are substantially enclosed within a housing that is mounted to a non-rotating vehicle component. The output shaft is solely supported by a pair of bearings for rotation relative to the housing. The bearings are installed for direct engagement with the output shaft and housing.

Abstract: A transfer case assembly includes an input gear, an idler gear, and an output gear. The idler gear is mounted on an idler shaft, which is rotatably supported by a bearing retained within a carrier. The carrier fits within an arcuate slot. The arcuate slot defines a multiple of idler shaft predetermined mounting locations. Each of the idler shaft predetermined mounting locations are equidistant from the third axis, and vary in distance from the first axis. For each of the idler shaft predetermined mounting locations a gear, of a predetermined size is provided to achieve a proper gear mesh for the desired gear ratio.

Abstract: A low cost brake sensor incorporates a sensor portion extending through one of the rivet holes in the backing plate of the brake pad. A locking sleeve snaps onto the sensor portion and secures the sensor to the backing plate. Preferably, the locking sleeve has a lip which snaps into a groove in an outer periphery of a sensor portion. The present invention thus provides a relatively low cost and secure way for attaching the sensor to the brake pad. No modification of the lining or the backing plate is necessary.

Abstract: A brake shoe assembly provides a plurality of drain openings located through a brake shoe table which correspond with drain openings in a brake lining. The aligned drain openings provide an unobstructed moisture escape path from an inner surface of the brake shoe table to minimize moisture retention and the possibility of corrosion.

Abstract: A torsion bar suspension assembly is provided that includes a control arm supported by a frame. The torsion bar extends along a longitudinal axis having a first end portion connected to the control arm and a second end portion engaging the frame. A contact arm is connected to the torsion bar and is arranged between the first and second end portions. The contact arm is spaced from the frame in a first position and engages the frame in a second position. A first spring rate is provided when the contact arm is spaced from the frame between the first and second positions. Once the contact arm engages the frame between second and third positions, a second spring rate is provided that is different from the first spring rate.

Abstract: A wheel hub assembly including first and second bearing assemblies positioned on opposite sides of a spacer. The spacer includes at least one opening to allow lubricant to flow through the spacer. The spacer includes a first section deformable such that an overall length of the spacer is reduced a predetermined amount in response to the application of a predetermined load to set a distance between the first and second bearing assemblies. The assembly further includes a spindle having external threads and a nut having internal threads engaged with the spindle to secure the bearing assemblies and spacer within the wheel hub assembly.

Abstract: A suspension module for use with an independent suspension system includes a subframe having a pair of subframe rails and a bridge supported therebetween. A pair of semi-trailing arms are pivotally attached to the subframe rails. Each semi-trailing arm includes an airbag support onto which an airbag is mounted. The airbags are positioned between the airbag supports and the subframe rails. A shock absorber extends from the semi-trailing arms to the subframe rails. A drive line brings rotational drive from a transmission to a carrier housing attached to the bridge of the subframe. A carden shaft extends from the carrier housing to spindles attached to the semi-trailing arms to transmit rotational drive from the carrier housing to the spindles.

Abstract: An independent suspension undercarriage module includes a first subframe segment and a second subframe segment. The subframe is manufactured of a composite material to provide a truss-like structural unibody which is mounted as a unit to the underside of a low floor vehicle through a plurality of resilient dampers. Passengers are thereby provided with a secondary vibration isolation structure separate from the suspension systems which filter out high frequency content generated by the suspension systems.

Abstract: An apparatus and method of forming a differential assembly is provided that includes the steps of providing a ring gear, which is preferably produced by a precision forging process. The differential case is cast about a portion of the ring gear to secure the ring gear to the differential case and form the differential assembly. Preferably, the ring gear includes projections that are embedded in the differential case during the casting process to enhance the connection between the ring gear and the differential case. In this manner, the ring gear may be constructed from a forged steel and the differential case may be constructed from ductile iron while eliminating the fasteners of the prior art.

Abstract: A vehicle tire inflation system includes an axle assembly with an axle housing having an air supply conduit. Air is provided to the air supply conduit from an air tank mounted on the vehicle. The axle includes least one wheel hub rotatably supported on the axle housing by bearings. A hub cap is mounted at one end of the wheel hub and has an air passageway for conducting an air supply through the hub cap to a tire. A filter is installed within the passageway to remove any debris from the air supply.

Abstract: A first and second hub assembly supported by an independent suspension system allows the independent articulation of each hub assembly. An input gear box includes a reduction gear set that drives a reduction gear set at each hub assembly. The input gear box is mounted offset from the first axis and the vehicle longitudinal axis to simultaneously drive both hub assemblies to allow a lowered vehicle floor profile.

Abstract: A suspension assembly is provided that includes a first suspension member such as a rear axle housing having first and second opposing sides. The housing includes spaced apart corners. First and second seats are respectively adjacent to the first and second opposing sides. Each of the seats has inwardly facing surfaces interconnected by an intermediate surface with the inwardly facing surfaces engaging the corners and the intermediate surface spaced from the side. The intermediate surface and inwardly facing surfaces of each seat form a continuous unbroken surface with the inwardly facing surfaces facing one another. A fastener such as a U-bolt or a pair of bolts secure the first and second seat about the first suspension member to secure a second suspension member to the first suspension member.

Abstract: A vehicle brake assembly utilizes a damping mechanism to eliminate brake linings. The brake assembly includes a fixed base plate and an actuation plate rotatable relative to the base plate. The base plate includes a plurality of orientation slots and the actuation plate includes a plurality of actuation slots with each one of the actuation slots partially overlapping one of the orientation slots. A cam having a plurality of cam-lobes formed about the circumference is mounted for rotation with an axle shaft. A plurality of dampers interact with the cam to brake the vehicle. Each damper includes a mounting portion that extends through one of the orientation slots and the corresponding actuation slot, and which has a movable distal end that engages the cam. A motor and gear assembly control rotation of the actuation plate and cause the distal ends of the dampers to engage the cam to perform a brake actuation.

Abstract: A vehicle suspension includes a dock height holding device. First and second jounce bumper portions preferably each include a surface configuration that faces generally toward the oppositely facing jounce bumper portion. By moving at least one of the jounce bumper portions between first and second alignment positions, the clearance between suspension components is controlled in a manner that controls the height of a truck bed or trailer deck. In one example, each jounce bumper portion includes four projections and four spaced recesses. In the first alignment position the projections on one jounce bumper portion are received within the recesses on the oppositely facing portion during normal driving conditions. In the second alignment position, the projections of the jounce bumper portions engage each other and maintain a larger clearance between the suspension components to ensure an appropriate deck height when the vehicle is parked for loading or unloading.

Abstract: A suspension system includes a swing arm which pivots about a pivot axis. A hub assembly, hub gear box and input gear box are mounted to an independently pivoting swing arm. The pivot axis is located closer to the ground than a rotational axis defined by the hub assemblies and the input gear box. A coupling extends from the input gear box to receive an input driveline from a drive source such as vehicle engine. The coupling is located proximate the pivot axis to minimize relative movement during articulation of the swing arm. An axle housing extends between the input gear box and an opposite hub gear box to support a drive shaft and serves as a torsion bar.

Abstract: A vehicle suspension assembly includes a height holding device that is at least partially supported within an air spring of the suspension assembly. The height holding device includes a hydraulic ram. A moveable portion of the hydraulic ram moves between a first position where a minimum clearance is maintained between suspension components and a second position where a larger clearance is maintained between the suspension components. The height holding device moves into the second position to maintain a desired height of the truck or trailer bed during loading and unloading operations at a loading dock, for example. The height holding device allows for the suspension air springs to be evacuated of air pressure during loading or unloading conditions without a change in deck height.

Abstract: A retainer clip is used to maintain proper shoe contact and orientation for a cam actuated brake assembly. The cam actuated brake assembly includes a pair of brake shoes each having an anchor end and an actuation end. Each brake shoe is pivotally mounted at the anchor end to a brake spider with an anchor pin. When brakes are applied, a cam acts against the actuation end causing the brake shoes to pivot about axes defined by the anchor pins. Preferably the retainer clip is mounted to the brake shoe and includes a pair of hooks that support opposite ends of the anchor pin. The retainer clip cooperates with the anchor pins to maintain proper shoe geometry.

Abstract: A driveline assembly includes a shaft that is rotatably supported on a bearing assembly within a drive axle. The shaft has a first mount portion with a threaded exterior surface and a second mount portion with a splined exterior surface. A retaining ring is threaded onto the first mount portion to engage and retain the bearing assembly at a proper location. A yoke member with a splined inner bored is mounted on the shaft in engagement with the splined exterior surface. The yoke member can easily be connected and disconnected from the shaft without having to remove the retaining ring. The yoke member also includes a quick disconnect device that simplifies removal and re-assembly of the yoke member from the shaft.