Abstract: A rigid drive axle assembly includes a support beam member having a substantially flat central plate section, a differential assembly module secured to the central plate section through at least two threaded studs extending from the central plate section. The differential assembly module includes a differential carrier frame member having two bearing hubs receiving differential bearings. A method for verifying a predetermined bearing preload of the differential assembly module comprises the steps of preloading the differential bearings to the predetermined bearing preload, inserting mounting bores in the bearing hubs of the frame member onto the mounting studs, and determining that the differential bearings are properly preloaded if the mounting studs are received in the mounting bores in the differential carrier frame member without substantial resistance, or determining that the differential bearings are not properly preloaded if the mounting studs may not be received in the mounting bores easily.

Abstract: A drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central plate section and two opposite arm sections, a differential assembly module secured to the central plate section and enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central plate section. A method for assembling the drive axle assembly comprises the steps of securing the front cover to a front mounting surface of the support beam member, fastening the differential assembly module to the central plate section of the support beam member, and fastening the rear cover to the rear mounting surface of the support beam member.

Abstract: A drive axle assembly for a motor vehicle comprises a support beam member, a differential assembly module secured to the support beam member and a cover member fastened to the support beam member to cover at least a portion the differential assembly module. The cover member includes two spaced access openings with adjustable sealing flange devices for sealing an interior cavity within the cover member between the access openings and corresponding axle shaft members. The sealing flange device is positionally adjustable relative to the cover member. A method for adjusting position of the sealing flange device relative to the cover member comprises the steps of securing the cover member to the axle support member, mounting the sealing flange device to the cover member, adjusting the position of the sealing flange device relative to the cover member and securing the sealing flange device to the cover member.

Abstract: A differential carrier, adapted to rotatably support a differential assembly and a final drive assembly, includes an integrally formed cage-type differential carrier frame member comprising a pair of axially spaced pinion support members for rotatably supporting a pinion drive shaft, a pair of laterally spaced opposite differential support members for rotatably supporting a differential case, at least one first arm member interconnecting the pinion support members, and at least two second arm members each interconnecting at least one of the pinion support members with one of the differential support members to thereby define a cage-type space frame of the differential carrier. The differential carrier frame member further comprises a continuous flange member integrally secured to the differential support members and defining a rear access opening in the differential carrier, and a mounting member for mounting the differential carrier to a vehicle sprung mass.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.

Abstract: A rigid drive axle assembly for motor vehicles, includes a support beam member having a substantially flat, enlarged central section and two opposite arm sections axially outwardly extending from the central section, a differential assembly secured to the flat central section of the support beam member, and two opposite axle shaft members outwardly extending from the differential assembly and rotatably supported by the arm sections in a spaced relationship with respect to the central section of the support beam member. The differential assembly includes a differential carrier frame member fastened to the central section of the support beam member, and provided for rotatably supporting a differential case and a drive pinion. The differential assembly is enclosed into a housing formed by a rear cover and a front cover secured to opposite surfaces of the central section of the support beam member. The rear cover incorporates two throughholes provided with self-centering seals.