Abstract: The damper assembly includes a tubular member, a rod, a primary piston, a secondary piston, and a resilient member. The tubular member includes a sidewall and a cap positioned at an end of the sidewall. The sidewall and the cap define an inner volume. The sidewall includes a shoulder separating the tubular member into a first portion and a second portion. The resilient member is disposed between the secondary piston and the cap and thereby is positioned to bias the secondary piston into engagement with the shoulder.

Abstract: A vehicle includes a passenger capsule, a front module, a rear module, an engine, a transaxle, a front lift structure, and a rear lift structure. The front module is coupled to a front end of the passenger capsule. The front module includes a first longitudinal frame member, a second longitudinal frame member, and a front axle assembly. The rear module is coupled to a rear end of the passenger capsule and includes a rear axle assembly. The engine is coupled to the front module. The transaxle is coupled to the rear module. The transaxle includes a housing. The rear axle assembly includes a component that is directly coupled to the housing of the transaxle. The front lift structure includes protrusions extending from the first longitudinal frame member and the second longitudinal frame member. The rear lift structure includes protrusions extending from opposing lateral sides of the structural shell.

Abstract: A military vehicle includes a passenger capsule including a roof, a floor, and sidewalls that define an interior, a driver seat and a passenger seat disposed within the interior of the passenger capsule, and a belly deflector coupled to an exterior of the passenger capsule and positioned beneath the floor. The belly deflector is spaced from the floor such that the floor is configured as a floating floor. The floor and the belly deflector provide two levels of underbody protection.

Abstract: A military vehicle includes a brake positioned to facilitate braking a tractive element, a brake housing defining an inner volume, a piston separating the inner volume into a first chamber and a second chamber, a rod extending through an end of the brake housing and coupled to the piston where the rod is positioned to selectively engage with the brake to inhibit movement of the tractive element, a resilient member positioned within the inner volume and configured to generate a biasing force against the piston such that the rod is biased into engagement with the brake, and an air-to-hydraulic intensifier coupled to the brake housing. The air-to-hydraulic intensifier is configured to receive a supply of air and provide a hydraulic fluid to the brake housing based on the supply of air to overcome the biasing force to disengage the rod from the brake to permit movement of the tractive element.

Abstract: A military vehicle includes a chassis, a front axle coupled to the chassis, a rear axle coupled to the chassis, and a suspension system. The suspension system include a front suspension assembly and a rear suspension assembly. The front suspension assembly is positioned between the chassis and the front axle. The rear suspension assembly is positioned between the chassis and the rear axle. Each of the front suspension assembly and the rear suspension assembly includes a first spring, a second spring, a first hydraulic damper, and a second hydraulic damper. The first hydraulic damper and the second hydraulic damper of at least one of the front suspension assembly or the rear suspension assembly are cross-plumbed to provide a hydraulic body roll control function and eliminate the need for an anti-roll bar.

Abstract: A suspension element includes a main body having an end cap defining an internal volume and a tubular element slidably engaged with the main body. The suspension element further includes a first piston and a flow control element. The flow control element is configured to prevent movement of the tubular element relative the main body in a direction. The suspension element may further include a locking member and a piston. The locking member may be configured to engage a barrier of the main body when the first piston traverses at least a predetermined distance towards the end cap. The locking member may be affixed to the tubular element and may fully surround the tubular element. Together the flow control element and the locking member are configured to prevent movement of the suspension element.

Abstract: A vehicle suspension system includes a gas spring. The gas spring includes a cylinder and a rod movable relative to the cylinder. The rod and the cylinder at least partially define a chamber having a variable volume and containing a first pressurized gas therein. The gas spring further includes an accumulator in communication with the chamber and containing a second pressurized gas therein. The gas spring provides a first spring rate when the first pressurized gas is pressurized below a threshold pressure and a second spring rate when the first pressurized gas is pressurized above the threshold pressure.

Abstract: A drive train for a vehicle includes a first electromagnetic device, a second electromagnetic device electrically coupled to the first electromagnetic device by an electrical power transmission system, and an engine coupled to the first electromagnetic device and configured to drive the first electromagnetic device to provide electrical energy. In all modes of operation where the engine drives the first electromagnetic device to provide the electrical energy, the first electromagnetic device operates without providing the electrical energy to an energy storage device.

Abstract: The damper assembly includes a tubular member, a rod, a primary piston, a secondary piston, and a resilient member. The tubular member includes a sidewall and a cap positioned at an end of the sidewall. The sidewall and the cap define an inner volume. The sidewall includes a shoulder separating the tubular member into a first portion and a second portion. The resilient member is disposed between the secondary piston and the cap and thereby is positioned to bias the secondary piston into engagement with the shoulder.

Abstract: A military vehicle includes a passenger capsule having a front end and a rear end, a front module coupled to the front end, and a rear module coupled to the rear end. The front module includes a front axle, a front differential, an engine, and a transmission. The front differential is coupled to the front axle. The front differential functions as a structural component of the front module. The front differential defines an engine mount. The engine is at least partially supported by the engine mount of the front differential. The transmission is coupled to the engine. The rear module includes a rear axle and a transaxle. The transaxle includes a housing, a transfercase disposed within the housing, and a rear differential disposed within the housing. The transfercase is coupled to the transmission, the front differential, and the rear differential. The rear differential is coupled to the rear axle.

Abstract: A military vehicle includes a passenger capsule, a front module coupled to a front end of the passenger capsule, and a rear module coupled to a rear end of the passenger capsule. The passenger capsule has a frame rail-less monocoque hull structure. The front module includes a first longitudinal frame member coupled to the front end of the passenger capsule proximate a first side thereof, a second longitudinal frame member coupled to the front end of the passenger capsule proximate an opposing second side thereof, and an underbody support structure coupled to the front end of the passenger capsule, the first longitudinal frame member, and the second longitudinal frame member. The underbody support structure is positioned beneath the first longitudinal frame member and the second longitudinal frame member.

Abstract: A damper assembly includes a tubular member including a sidewall and a shoulder. The damper assembly includes a rod and a piston coupled to the rod. A secondary piston has a second contact surface, an opposing second surface, an inner cylindrical face defining a central aperture that receives the rod, and an outer cylindrical face. The opposing second surface includes one or more surface grooves, extending between the inner cylindrical face and the outer cylindrical face along the opposing second surface, and one or more bypass orifices disposed about the body member. The bypass orifices extend along the inner cylindrical face between the second contact surface and the opposing second surface. The secondary piston defines a channel extending between the inner cylindrical face and an outer periphery of the body member. The channel and bypass orifices form a fluid flow path when the piston contacts the secondary piston.

Abstract: A military vehicle includes a passenger capsule, a front module coupled to a front end of the passenger capsule, a rear module coupled to a rear end of the passenger capsule, a front axle coupled to the front module, a rear axle coupled to the rear module, an engine coupled by the front module, a front differential coupled to the front axle, a transaxle, and an actuator. The transaxle is coupled to the engine, the rear axle, and the front differential. The transaxle includes an internal mechanical disconnect that facilitates decoupling the transaxle from the front differential. The actuator is accessible from an exterior of the passenger capsule to engage the internal mechanical disconnect.

Abstract: The damper assembly includes a tubular member, a rod, a primary piston, a secondary piston, and a resilient member. The tubular member includes a sidewall and a cap positioned at an end of the sidewall. The sidewall and the cap define an inner volume. The sidewall includes a shoulder separating the tubular member into a first portion and a second portion. The resilient member is disposed between the secondary piston and the cap and thereby is positioned to bias the secondary piston into engagement with the shoulder.

Abstract: A drive train for a vehicle includes a first electromagnetic device, a second electromagnetic device electrically coupled to the first electromagnetic device by an electrical power transmission system, and an engine coupled to the first electromagnetic device and configured to drive the first electromagnetic device to provide electrical energy. In all modes of operation where the engine drives the first electromagnetic device to provide the electrical energy, the first electromagnetic device operates without providing the electrical energy to an energy storage device.

Abstract: A vehicle has a vehicle body and a vehicle suspension system supporting the vehicle body. The vehicle suspension has a gas spring, and includes a cylinder, a rod, and an accumulator. The cylinder has a longitudinal axis. The rod is partially disposed within the cylinder and is movable relative to the cylinder along the longitudinal axis of the cylinder. The rod and cylinder together at least partially define a chamber having a variable volume that receives a first pressurized gas. The accumulator is in communication with the chamber and contains a second pressurized gas held at a threshold pressure creating a first spring rate opposing relative movement between the rod and cylinder when the first pressurized gas within the chamber is pressurized below the threshold pressure and a second spring rate when the first pressurized gas within the chamber is pressurized above the threshold pressure.

Abstract: A vehicle includes a body, a pair of front gas springs coupling a pair of front wheel end assemblies to the body, and a pair of rear gas springs coupling a pair of rear wheel end assemblies to the body. At least one of the rear gas springs includes a cylinder, a rod extending within the cylinder and movable relative to the cylinder, the rod and the cylinder together at least partially defining a chamber having a variable volume and receiving a first pressurized gas therein, and an accumulator in communication with the chamber and containing a second pressurized gas therein. The second pressurized gas within the accumulator is held at a threshold pressure creating a first spring rate when the first pressurized gas is below the threshold pressure and a second spring rate when the first pressurized gas is above the threshold pressure.

Abstract: A damper assembly includes an outer cylinder, an inner cylinder, a plunger, a passage, and a piston. The inner cylinder is positioned at least partially within the outer cylinder and has a cap attached to one end thereof. The plunger is positioned radially inward from the inner cylinder and coupled to a rod. The plunger, the cap, and an interior of the inner cylinder at least partially define a first chamber. The passage extends through the rod and is fluidly coupled with the first chamber. The piston is coupled to the inner cylinder and extends radially outward toward the outer cylinder. The piston, an exterior surface of the inner cylinder, and the outer cylinder at least partially define a second chamber. The plunger is configured to move relative to the inner cylinder, and the piston is configured to move relative to the outer cylinder.

Abstract: A damper assembly includes an outer cylinder, an inner cylinder positioned at least partially within the outer cylinder, a cap coupled to the inner cylinder, and a plunger positioned radially inward from the inner cylinder and coupled to a rod. The plunger, the cap, and an interior of the inner cylinder at least partially define a first chamber. The suspension system further includes a passage extending through the rod and fluidly coupled with the first chamber, a piston coupled to the inner cylinder and extending radially outward toward the outer cylinder, a first port in fluid communication with the plunger through the passage, and a second port in fluid communication with the piston. The piston, an exterior surface of the inner cylinder, and the outer cylinder at least partially define a second chamber.

Abstract: A vehicle includes a body, a pair of front gas springs coupling a pair of front wheel end assemblies to the body, and a pair of rear gas springs coupling a pair of rear wheel end assemblies to the body. At least one of the rear gas springs includes a cylinder, a rod extending within the cylinder and movable relative to the cylinder, the rod and the cylinder together at least partially defining a chamber having a variable volume and receiving a first pressurized gas therein, and an accumulator in communication with the chamber and containing a second pressurized gas therein. The second pressurized gas within the accumulator is held at a threshold pressure creating a first spring rate when the first pressurized gas is below the threshold pressure and a second spring rate when the first pressurized gas is above the threshold pressure.