Abstract: A method for servicing a portal gear box assembly and/or a braking system is disclosed. The method includes removing the wheel hub from the output shaft, removing the front cover from the housing of the assembly, and removing the clutch pack. The portal gear box/braking assembly is serviced and the clutch pack is installed over the output shaft, the place plate is re-installed, and the wheel hub is installed onto the output shaft. The portal gear box of the present disclosure includes a clutch pack comprising a first and second set of clutch plates interspersed between each other. The first set of clutch plates configured to rotate with rotation of the output shaft and the second set configured to not rotate. The clutch pack is compressible by a hydraulic piston and pressure plate, compressing the sets of the clutch plates reducing the rotation of the output shaft.

Abstract: A portal gear box assembly for an off-road vehicle that includes a housing that defines an input gear subassembly indent, an output gear subassembly indent, and one or more idler-gear subassembly indents. The assembly includes an input gear subassembly positioned in the input gear subassembly indent with an input gear connected to an input shaft, an output gear subassembly positioned in the output gear subassembly indent with an output gear connected to an output shaft, and an idler-gear subassembly positioned within the one or more idler-gear subassembly indents to connect the input and output gears with a removable adaptor that is selectively positionable in more than one configuration to alter the transmission ratio between the input and output gears.

Abstract: A braking system for a portal lift assembly includes a shaft operably connected to a vehicle power source and effective to directly or indirectly rotate a wheel of the vehicle upon rotation of the shaft about its axis, a piston positioned along the shaft and effective for applying an axial force along the axis of the shaft, a fluid channel fillable with a non-compressible fluid and effective to apply a hydraulic force to the piston when pressure is applied to fluid in the line, a pressure plate positioned along the shaft and effective for applying an axial force along the axis of the shaft in response to the application of an axial force by the piston. A clutch pack is positioned between the pressure plate and the piston, and includes two sets of clutch plates radially surrounding the shaft. The first set of clutch plates is connected to the shaft in a manner effective to cause those clutch plates to rotate about the axis of the shaft when the shaft rotates.

Abstract: A portal gear box assembly effective to lift and change the gear ratio of a wheel of an off-road vehicle includes a housing, an input gear sub-assembly, an output gear sub-assembly, and an idler gear sub-assembly effective for linking the input gear to the output gear. The input gear sub-assembly includes an input gear, the output gear sub-assembly includes an output gear, and the idler gear sub-assembly includes at least one idler gear and at least one removable adaptor effective for holding the idler gear in either a first position or a second position different from the first position. The sub-assemblies may also include bearings to facilitate movement of the gears.

Abstract: A mounting system for a portal lift assembly of an off-road vehicle includes a housing having a rear wall, a front wall, and a side wall. The rear wall includes an opening to receive the end of one of the vehicle's axles, and the front wall includes an opening to allow an output shaft to extend outward from the housing. The rear wall also includes an integral mounting brackets effective to mount the box to an upper A-arm to the rear wall, and a lower A-arm to the rear wall.

Abstract: A vibration-reducing portal box assembly for mounting a wheel of an off-road vehicle includes a housing with a receptacle adapted to receive a stock axle shaft of an off-road vehicle, an output shaft operably connectable to a stock axle received in the housing and effective to rotate upon rotation of said stock axle, and a wheel hub having a central opening adapted to receive said output shaft, and adapted to turn a wheel mounted to said wheel hub upon rotation of said output shaft. The output shaft has a tapered portion connecting its proximal end to its distal end. The wheel hub has a tapered portion adapted to matingly receive the tapered portion of the output shaft. The output shaft may be connected to the stock axle shaft by a geared linking mechanism.

Abstract: A portal gear box assembly effective to lift and change the gear ratio of a wheel of an off-road vehicle includes a housing, an input gear sub-assembly, an output gear sub-assembly, and an idler gear sub-assembly effective for linking the input gear to the output gear. The input gear sub-assembly includes an input gear, the output gear sub-assembly includes an output gear, and the idler gear sub-assembly includes at least one idler gear and at least one removable adaptor effective for holding the idler gear in either a first position or a second position different from the first position. The sub-assemblies may also include bearings to facilitate movement of the gears.

Abstract: A portal gear box assembly for an all-terrain vehicle includes a sealed portal gear box housing having an interior housing space that contains a set of gears for linking an axle to an output shaft. An expandable space is in fluid communication with the interior housing space, and is adapted to allow pressurized fluid contained in the interior housing space to flow into the expandable space, thus expanding the volume of the expandable space and reducing the pressure within the interior housing space. The expandable space may be provided in the form of a bellows whose volume can be changed by expansion or contraction of a fluid contained therein. A fluid is contained within the portal gear box housing and within the expandable space. The expandable space may be mounted externally to the portal gear box housing, and may be connected to the portal gear box housing by a conduit effective for allowing fluid to pass between the portal gear box housing and the expandable space.

Abstract: A portal gear box assembly for an all-terrain vehicle includes a sealed portal gear box housing having an interior housing space that contains a set of gears for linking an axle to an output shaft. An expandable space is in fluid communication with the interior housing space, and is adapted to allow pressurized fluid contained in the interior housing space to flow into the expandable space, thus expanding the volume of the expandable space and reducing the pressure within the interior housing space. The expandable space may be provided in the form of a bellows whose volume can be changed by expansion or contraction of a fluid contained therein. A fluid is contained within the portal gear box housing and within the expandable space. The expandable space may be mounted externally to the portal gear box housing, and may be connected to the portal gear box housing by a conduit effective for allowing fluid to pass between the portal gear box housing and the expandable space.

Abstract: A portal gear box assembly for an all-terrain vehicle includes a sealed portal gear box housing having an interior housing space that contains a set of gears for linking an axle to an output shaft. An expandable space is in fluid communication with the interior housing space, and is adapted to allow pressurized fluid contained in the interior housing space to flow into the expandable space, thus expanding the volume of the expandable space and reducing the pressure within the interior housing space. The expandable space may be provided in the form of a bellows whose volume can be changed by expansion or contraction of a fluid contained therein. A fluid is contained within the portal gear box housing and within the expandable space. The expandable space may be mounted externally to the portal gear box housing, and may be connected to the portal gear box housing by a conduit effective for allowing fluid to pass between the portal gear box housing and the expandable space.

Abstract: A portal box assembly for mounting a wheel to an off road vehicle in a lifted and extended wheelbase position. The assembly includes a portal gear box having an input shaft opening for an input shaft, and an output shaft extending from an output shaft opening. The portal gear box also includes a set of gears effective to transmit power from the input shaft to the output shaft, and optionally to reduce the gear ratio. The assembly is mountable to the vehicle in an extended wheelbase position in which the output shaft is positioned below and forward of the input shaft when the assembly is used to mount a forward wheel, and in which the output shaft is positioned below and rearward of the input shaft when the assembly is used to mount a rear wheel.

Abstract: A vibration-reducing portal box assembly for mounting a wheel of an off-road vehicle includes a housing with a receptacle adapted to receive a stock axle shaft of an off-road vehicle, an output shaft operably connectable to a stock axle received in the housing and effective to rotate upon rotation of said stock axle, and a wheel hub having a central opening adapted to receive said output shaft, and adapted to turn a wheel mounted to said wheel hub upon rotation of said output shaft. The output shaft has a tapered portion connecting its proximal end to its distal end. The wheel hub has a tapered portion adapted to matingly receive the tapered portion of the output shaft. The output shaft may be connected to the stock axle shaft by a geared linking mechanism.

Abstract: An adjustable portal box assembly for selectively mounting a wheel to an off road vehicle in either of two positions. The assembly includes a mounting plate mountable to the suspension of an off road vehicle, and a portal box is mountable to the mounting plate. The portal box includes an input shaft opening for an input shaft, and an output opening for an output shaft. The portal box is mountable to the mounting plate in a first position in which the output shaft is positioned to extend the wheelbase relative to the input shaft, or in a second position in which the output shaft is positioned in vertical alignment with the input shaft.

Abstract: An adjustable portal box assembly for selectively mounting a wheel to an off road vehicle in either of two positions. The assembly includes a mounting plate mountable to the suspension of an off road vehicle, and a portal box is mountable to the mounting plate. The portal box includes an input shaft opening for an input shaft, and an output opening for an output shaft. The portal box is mountable to the mounting plate in a first position in which the output shaft is positioned to extend the wheelbase relative to the input shaft, or in a second position in which the output shaft is positioned in vertical alignment with the input shaft.

Abstract: An adjustable portal box assembly for selectively mounting a wheel to an off road vehicle in either of two positions. The assembly includes a mounting plate mountable to the suspension of an off road vehicle, and a portal box is mountable to the mounting plate. The portal box includes an input shaft opening for an input shaft, and an output opening for an output shaft. The portal box is mountable to the mounting plate in a first position in which the output shaft is positioned to extend the wheelbase relative to the input shaft, or in a second position in which the output shaft is positioned in vertical alignment with the input shaft.

Abstract: An adjustable portal box assembly for selectively mounting a wheel to an off road vehicle in either of two positions. The assembly includes a mounting plate mountable to the suspension of an off road vehicle, and a portal box is mountable to the mounting plate. The portal box includes an input shaft opening for an input shaft, and an output opening for an output shaft. The portal box is mountable to the mounting plate in a first position in which the output shaft is positioned to extend the wheelbase relative to the input shaft, or in a second position in which the output shaft is positioned in vertical alignment with the input shaft.

Abstract: A vibration-reducing portal box assembly for mounting a wheel of an off-road vehicle includes a housing with a receptacle adapted to receive a stock axle shaft of an off-road vehicle, an output shaft operably connectable to a stock axle received in the housing and effective to rotate upon rotation of said stock axle, and a wheel hub having a central opening adapted to receive said output shaft, and adapted to turn a wheel mounted to said wheel hub upon rotation of said output shaft. The output shaft has a tapered portion connecting its proximal end to its distal end. The wheel hub has a tapered portion adapted to matingly receive the tapered portion of the output shaft. The output shaft may be connected to the stock axle shaft by a geared linking mechanism.

Abstract: A vibration-reducing portal box assembly for mounting a wheel of an off-road vehicle includes a housing with a receptacle adapted to receive a stock axle shaft of an off-road vehicle, an output shaft operably connectable to a stock axle received in the housing and effective to rotate upon rotation of said stock axle, and a wheel hub having a central opening adapted to receive said output shaft, and adapted to turn a wheel mounted to said wheel hub upon rotation of said output shaft. The output shaft has a tapered portion connecting its proximal end to its distal end. The wheel hub has a tapered portion adapted to matingly receive the tapered portion of the output shaft. The output shaft may be connected to the stock axle shaft by a geared linking mechanism.

Abstract: An adjustable portal box assembly for selectively mounting a wheel to an off road vehicle in either of two positions. The assembly includes a mounting plate mountable to the suspension of an off road vehicle, and a portal box is mountable to the mounting plate. The portal box includes an input shaft opening for an input shaft, and an output opening for an output shaft. The portal box is mountable to the mounting plate in a first position in which the output shaft is positioned to extend the wheelbase relative to the input shaft, or in a second position in which the output shaft is positioned in vertical alignment with the input shaft.

Abstract: A mounting system for a portal lift assembly of an off-road vehicle includes a housing having a rear wall, a front wall, and a side wall. The rear wall includes an opening to receive the end of one of the vehicle's axles, and the front wall includes an opening to allow an output shaft to extend outward from the housing. The rear wall also includes one or more integral mounting brackets effective to mount the box to the suspension of the vehicle. Such integral mounting brackets may include an upper A-arm connection bracket to connect the upper A-arm directly to the rear wall, and/or a lower A-arm connection bracket to connect the lower A-arm directly to the rear wall. When the wheel is a steerable wheel, the rear wall also may include an integral mounting bracket effective to allow a steering linkage to connect directly to the rear wall.