Abstract: An axle assembly having an axle shaft subassembly. The axle shaft subassembly may include an axle shaft and an adapter ring. The adapter ring may receive the axle shaft and may be fixedly positioned with respect to the axle shaft. A hub may receive the adapter ring and may be fixedly positioned with respect to the adapter ring.

Abstract: A one-piece axle and a method of manufacture. The method may include providing a one-piece axle blank that has a shaft and a flange. The shaft may have a hole that may extend along an axis. The flange may extend radially outward from an end of the shaft. The shaft may be radially forged against a first mandrel to axially elongate the shaft.

Abstract: A one-piece axle and a method of manufacture. The method may include providing a one-piece axle blank that has a shaft and a flange. The shaft may have a hole that may extend along an axis. The flange may extend radially outward from an end of the shaft. The shaft may be radially forged against a first mandrel to axially elongate the shaft.

Abstract: An axle assembly having an axle shaft subassembly. The axle shaft subassembly may include an axle shaft and an adapter ring. The adapter ring may receive the axle shaft and may be fixedly positioned with respect to the axle shaft. A hub may receive the adapter ring and may be fixedly positioned with respect to the adapter ring.

Abstract: A differential includes first and second case members that are attached to each other to define an inner cavity that receives a differential gear assembly. A first tapered roller bearing is associated with the first case member and a second tapered roller bearing is associated with the second case member. One of the first and second tapered roller bearings is inverted such that a defining taper diverges towards the differential gear assembly. The other of the first and second tapered roller bearings is non-inverted with a defining taper diverging in a direction that faces away from the differential gear assembly.

Abstract: A differential includes first and second case members that are attached to each other to define an inner cavity that receives a differential gear assembly. A first tapered roller bearing is associated with the first case member and a second tapered roller bearing is associated with the second case member. One of the first and second tapered roller bearings is inverted such that a defining taper diverges towards the differential gear assembly. The other of the first and second tapered roller bearings is non-inverted with a defining taper diverging in a direction that faces away from the differential gear assembly.

Abstract: A suspension bracket is supported by an axle housing and is used to attach a vehicle suspension to the axle housing. The axle housing includes a polygonal cross-section including obliquely orientated corner portions that extend between adjacent vertical and horizontal walls. The suspension bracket includes a base portion, a pair of bracket legs, and contact pads that extend between each bracket leg and the base portion. Each bracket leg engages a protruding portion that extends outwardly from one of the vertical walls. A pressure force is applied to secure the suspension bracket to the axle housing. The pressure force squeezes the suspension bracket around the axle housing to generate a clamp load. The clamp load is exerted by the contact pads against the corner portions of the axle housing. Fore/aft loading and torsional loading are transferred from the axle housing to the suspension bracket via the corner portions.

Abstract: An axle housing includes a suspension mount interface for mounting a vehicle suspension to the axle housing. The axle housing includes a first leg portion extending to a first wheel assembly and a second leg portion extending to a second wheel assembly. The first and second leg portions each include a suspension mount interface. Each suspension mount interface includes first and second bracket portions. The first and second bracket portions are clamped together prior to attachment to the axle housing to form a suspension bracket assembly. One clamped suspension bracket assembly is then slid over each axle housing leg portion. The first and second bracket portions are subjected to a preload force as they are welded or fastened to each other, providing a preload effect to define a suspension load path that has positive contact only at desired locations on the axle housing.