Abstract: A joint is formed between first and second workpieces. The first workpiece defines a cavity, while the second workpiece includes a shear member. The shear member is at least partially inserted into the cavity to secure the first workpiece to the second workpiece. One of the workpieces has a lower hardness and/or shear strength than the other workpiece and includes at least one shear tab with a base portion and an end portion. In inserting the shear member into the cavity, the end portion of the shear tab is broken away from the base portion, leaving the base portion to extend between the cavity and the shear member, thereby securing the first workpiece to the second workpiece.

Abstract: A joint is formed between first and second workpieces. The first workpiece defines a cavity, while the second workpiece includes a shear member. The shear member is at least partially inserted into the cavity to secure the first workpiece to the second workpiece. One of the workpieces has a lower hardness and/or shear strength than the other workpiece and includes at least one shear tab with a base portion and an end portion. In inserting the shear member into the cavity, the end portion of the shear tab is broken away from the base portion, leaving the base portion to extend between the cavity and the shear member, thereby securing the first workpiece to the second workpiece.

Abstract: Steering knuckles integrating a brake mounting provisions are disclosed. The steering knuckles include a first, second piece and spindle. The first piece includes first and second mounting arms and each arm includes brake assembly engagement surfaces and brake assembly mounting bores, each of which can be modified to accommodate a number of different ways of removably connecting either a disc brake or drum brake to a steering knuckle.

Abstract: A suspension assembly having a frame hanger, a first control arm mounted between the frame hanger and an axle attachment member, a second control arm mounted to the frame hanger and to the axle attachment member, wherein the second arm extends from a centerline of the first control arm at an angle alpha such that the first control arm and the second control arm are not parallel to each other, wherein the centerline of the first control arm and the centerline of the second control arm extend to intersect at a point that is at a virtual center of rotation.

Abstract: A suspension assembly having a frame hanger, a first control arm mounted between the frame hanger and an axle attachment member, a second control arm mounted to the frame hanger and to the axle attachment member, wherein the second arm extends from a centerline of the first control arm at an angle alpha such that the first control arm and the second control arm are not parallel to each other, wherein the centerline of the first control arm and the centerline of the second control arm extend to intersect at a point that is at a virtual center of rotation.

Abstract: An axle coupling assembly and method for coupling a vehicle axle to an energy storing suspension component are disclosed. The assembly includes first and second U-shaped fastener assemblies, first and second flanges configured for connection to the vehicle axle, a mounting pad and a suspension component such as a leaf spring or a leading or trailing arm disposed between the first and second flanges and mounting pad.

Abstract: A suspension assembly having a frame hanger, a first control arm mounted between the frame hanger and an axle attachment member, a second control arm mounted to the frame hanger and to the axle attachment member, wherein the second arm extends from a centerline of the first control arm at an angle alpha such that the first control arm and the second control arm are not parallel to each other, wherein the centerline of the first control arm and the centerline of the second control arm extend to intersect at a point that is at a virtual center of rotation.

Abstract: Suspension systems, leaf springs and methods of providing a leaf spring in a suspension system are disclosed. The suspension systems, leaf springs and methods of providing a leaf spring in a suspension system allow use of a lighter weight leaf spring while providing customized roll stiffness and vertical spring rate that are complemented by a bumper that engages the leaf spring assembly when compressed to at least a preselected position.

Abstract: A shear spring having a base plate having a flat upper surface, and an upper plate having a V-shaped upper surface opposite the base plate adapted to mate with a corresponding V-shaped surface positioned on a side wall of a spring mount, the upper plate having a flat lower surface parallel to the flat upper surface of the base, and an elastomeric material positioned between the flat upper surface of the base plate and the flat lower surface of the upper plate.

Abstract: A suspension assembly having a frame hanger, a first control arm mounted between the frame hanger and an axle attachment member, a second control arm mounted to the frame hanger and to the axle attachment member, wherein the second arm extends from a centerline of the first control arm at an angle alpha such that the first control arm and the second control arm are not parallel to each other, wherein the centerline of the first control arm and the centerline of the second control arm extend to intersect at a point that is at a virtual center of rotation.

Abstract: A load cushion for a suspension system including a first cushion portion, a second cushion portion, a base plate having a flat top side and a bottom side, and a rate plate having a flat top side and a flat bottom side, wherein the top side of the base plate is parallel to the top side of the rate plate, wherein the first cushion portion extends away from the top side of the rate plate and has at least one vertical cross section having two tapering edges that extend towards each other as they extend upwardly from the top side of the rate plate until they end at an exposed upper surface, and wherein the second cushion portion extends between the top side of the base plate and the bottom side of the rate plate.

Abstract: A suspension having a frame attachment portion having an opening with a spring mount positioned therein, and a first shear spring positioned between a wall of the spring mount and a side wall of the opening, and a second shear spring positioned between another wall of the spring mount and another wall of the opening. The first spring mount comprises an inboard part and an outboard part with a first through-hole positioned therein adapted to allow passage of a first connecting rod therethrough, wherein the first connecting rod connects the inboard and outboard parts together, and wherein the first shear spring is compressed between a wall of the spring mount and a wall of the opening, and wherein the second shear spring is compressed between a wall of the spring mount and a wall of the opening.

Abstract: Suspension systems, leaf springs and methods of providing a leaf spring in a suspension system are disclosed. The suspension systems, leaf springs and methods of providing a leaf spring in a suspension system allow use of a lighter weight leaf spring while providing customized roll stiffness and vertical spring rate that are complemented by a bumper that engages the leaf spring assembly when compressed to at least a preselected position.

Abstract: A vehicle axle is provided with a main body defined by the combination of a channel having an inverted U-shaped configuration and a bottom plate. The ends of the main body are curved upwardly to define a pair of gooseneck portions. Axle head sections are formed at the ends of the axle and are closed off by end extensions extending from the front and rear walls of the channel and a cover flap extension extending from the top wall of the channel. A head plate having a rounded back edge and/or a pocket is inserted within the space between the cover flap and the top edges of the end extensions.

Abstract: A shear spring having a base plate having a flat upper surface, and an upper plate having a V-shaped upper surface opposite the base plate adapted to mate with a corresponding V-shaped surface positioned on a side wall of a spring mount, the upper plate having a flat lower surface parallel to the flat upper surface of the base, and an elastomeric material positioned between the flat upper surface of the base plate and the flat lower surface of the upper plate.

Abstract: A rotatable bar pin bushing assembly is disclosed for connecting components in a vehicular system, such as a suspension and/or axle system. The rotatable bar pin bushing assembly includes an inner sleeve, an outer sleeve positioned around the inner sleeve, and an insert positioned between the inner and outer sleeves. The rotatable bar pin bushing assembly also includes a bar pin rotatably positioned within the inner sleeve. The bar pin has at least one end with at least one bore extending therethrough to receive a fastener. The bar pin is rotatable within the inner sleeve to allow indexing of the bar pin for registering the at least one bore of the bar pin with a connector of a different component. A method for assembling the rotatable bar pin bushing assembly is also disclosed.

Abstract: A suspension system for supporting fore- and aft extending frame members of a vehicle chassis on a hollow axle, the system on one side of the vehicle being duplicated on the opposite side. Included in the suspension on each side are: (1) a frame bracket for pivotally supporting the fore or leading end of an asymmetric leaf spring; (2) a spring end support mounted on the frame side member for supporting the aft or trailing end of the leaf spring, and (3) a suitable assembly for attaching the leaf spring at a location intermediate its opposite ends to the axle so that the spring is divided into two cantilever limbs extending in opposite directions from the center line of the axle. The spring is formed so that one of the cantilever limbs has a stiffness substantially greater than the stiffness of the other limb. In all forms, at least one leaf of the asymmetric spring extends the full length of the spring.

Abstract: A tie-plate comprising a lower mounting flange that is removably attachable to a first frame hanger and to a second frame hanger, wherein the lower mounting flange includes a first set of attachment holes that correspond to a set of attachment holes at the first frame hanger, wherein the lower mounting flange includes a second set of attachment holes that correspond to a set of attachment holes at the second frame hanger, an extending member having a first end that extends at an angle from the lower mounting flange; and an upper mounting flange extending from a second end of the extending member, wherein the upper mounting flange has one or more mounting holes adapted for attachment of the tie-plate to an undercarriage of a vehicle.

Abstract: A suspension having a frame attachment portion having an opening with a spring mount positioned therein, and a first shear spring positioned between a wall of the spring mount and a side wall of the opening, and a second shear spring positioned between another wall of the spring mount and another wall of the opening. The first spring mount comprises an inboard part and an outboard part with a first through-hole positioned therein adapted to allow passage of a first connecting rod therethrough, wherein the first connecting rod connects the inboard and outboard parts together, and wherein the first shear spring is compressed between a wall of the spring mount and a wall of the opening, and wherein the second shear spring is compressed between a wall of the spring mount and a wall of the opening.

Abstract: A shear spring comprising a base and a V-shaped surface opposite the base adapted to mate with a corresponding V-shaped surface positioned on a side wall of a spring mount, and an elastomeric material positioned between the base and the V-shaped surface, wherein the base includes a first flange extending away from the V-shaped surface and adapted to be positioned outwardly from a first edge of a side wall of a spring module, and wherein the base includes a second flange extending away from the V-shaped surface and adapted to be positioned outwardly from a second edge of the side wall of the spring module, where the first flange and the second flange are positioned in parallel planes.