Abstract: A brake caliper mounting assembly that includes a steering knuckle, a brake caliper, and first and second mounting blocks. The first and second mounting blocks are mounted to the steering knuckle. The brake caliper is mounted on the first and second blocks.

Abstract: A steering knuckle assembly and a method of manufacture. The steering knuckle assembly may include a steering knuckle, a spindle, and a snap ring. The snap ring may be disposed in snap ring grooves in the steering knuckle and spindle to inhibit movement of the spindle with respect to the steering knuckle.

Abstract: A planetary wheel end assembly includes an axle shaft having an inboard end and an outboard end and a planetary gear assembly that receives driving input from the axle shaft. The planetary gear assembly includes a sun gear that is fixed for rotation with the axle shaft, a plurality of planet gears that are in meshing engagement with the sun gear, a non-rotating ring gear that is in meshing engagement with the planet gears, and a planetary spider that supports the plurality of planet gears. The planetary spider provides driving output to rotate a wheel component. The sun gear includes a sun gear body having a plurality of sun gear teeth in meshing engagement with the planet gears and a plurality of splines that are coupled with mating splines on the axle shaft. The plurality of splines are axially inboard of the plurality of sun gear teeth.

Abstract: A planetary wheel end assembly includes an axle shaft having an inboard end and an outboard end, a planetary gear assembly receiving driving input from the axle shaft, and a rotational support element that pilots the outboard end of the axle shaft. The planetary gear assembly includes a sun gear that is fixed for rotation with the axle shaft, a plurality of planet gears that are in meshing engagement with the sun gear, a non-rotating ring gear that is in meshing engagement with the planet gears, and a planetary spider that supports the plurality of planet gears. The planetary spider provides driving output to rotate a wheel component. The rotational support element is positioned radially between the outboard end of the axle shaft and planetary spider to allow relative rotation between the planetary spider and the outboard end of the axle shaft.

Abstract: A hypoid gear set for a vehicle drivetrain includes a pinion gear in meshing engagement with a ring gear. The hypoid gear set has a negative pinion offset. The hypoid pinion and ring gears provide a predetermined gear ratio that can be varied up to a fifty percent faster ratio within a single carrier packaging envelope defined by a maximum ring gear diameter.

Abstract: A planetary wheel end assembly includes an axle shaft having an inboard end and an outboard end, a planetary gear assembly receiving driving input from the axle shaft, and a rotational support element that pilots the outboard end of the axle shaft. The planetary gear assembly includes a sun gear that is fixed for rotation with the axle shaft, a plurality of planet gears that are in meshing engagement with the sun gear, a non-rotating ring gear that is in meshing engagement with the planet gears, and a planetary spider that supports the plurality of planet gears. The planetary spider provides driving output to rotate a wheel component. The rotational support element is positioned radially between the outboard end of the axle shaft and planetary spider to allow relative rotation between the planetary spider and the outboard end of the axle shaft.

Abstract: A planetary wheel end assembly includes an axle shaft having an inboard end and an outboard end and a planetary gear assembly that receives driving input from the axle shaft. The planetary gear assembly includes a sun gear that is fixed for rotation with the axle shaft, a plurality of planet gears that are in meshing engagement with the sun gear, a non-rotating ring gear that is in meshing engagement with the planet gears, and a planetary spider that supports the plurality of planet gears. The planetary spider provides driving output to rotate a wheel component. The sun gear includes a sun gear body having a plurality of sun gear teeth in meshing engagement with the planet gears and a plurality of splines that are coupled with mating splines on the axle shaft. The plurality of splines are axially inboard of the plurality of sun gear teeth.

Abstract: A leaf spring for a vehicle suspension is formed from a composite material and includes first and second ends that are longitudinally spaced apart from each other. A resilient element is attached to at least one of the first and second ends. The resilient element includes at least one hole that receives a connecting element. The resilient element and the connecting element cooperate to attach the leaf spring to a vehicle structure. In one example, the resilient element comprises a rubber block that is bonded to the leaf spring. In another example, the resilient element comprises a longitudinally orientated bushing that is inserted through a thickness of the leaf spring.

Abstract: At least one end of a longitudinally extending control link arm includes a laterally extending tubular portion that receives a bushing assembly. The tubular portion is used to pivotally secure an end of the control link arm to a vehicle structure or axle component. The bushing assembly is positioned within the tubular portion such that radial stiffness is distributed away from a center of the tubular portion. This configuration provides a high conical rate and provides auxiliary roll stiffness such that a sway bar is not required.

Abstract: A vehicle suspension includes trailing arm assemblies that have one end pivotally mounted to a first suspension rail, an opposite end with an air spring support formed with the trailing arm, and an axle mount portion that is mounted to an axle beam. A Panhard arm provides lateral stiffness and includes a first pivotal connection to the trailing arm and a second pivotal connection to a second suspension rail laterally spaced from the first suspension rail.

Abstract: A leaf spring for a vehicle suspension is formed from a composite material and includes a central portion to be supported by an axle and at least one free end that extends from the central portion in a longitudinal direction. The free end is coupled to a vehicle structure via a slider bracket. A contact element is mounted to the slider bracket to contact an upper surface of the free end to accommodate vertical forces. The free end is slidably movable relative to the contact element along a longitudinal axis and is pivotable relative to the contact element about a lateral axis.

Abstract: A spring is to be supported on an axle with a housing. The housing surrounds a portion of the spring and has a housing inner portion positioned between first and second housing end portions. A lining secures the spring to the housing. A portion of the lining at the first and second housing end portions is thicker than a portion of the lining at the housing inner portion.

Abstract: A leaf spring for a vehicle suspension is formed from a composite material and includes first and second ends that are longitudinally spaced apart from each other. A resilient element is attached to at least one of the first and second ends. The resilient element includes at least one hole that receives a connecting element. The resilient element and the connecting element cooperate to attach the leaf spring to a vehicle structure. In one example, the resilient element comprises a rubber block that is bonded to the leaf spring. In another example, the resilient element comprises a longitudinally orientated bushing that is inserted through a thickness of the leaf spring.

Abstract: At least one end of a longitudinally extending control link arm includes a laterally extending tubular portion that receives a bushing assembly. The tubular portion is used to pivotally secure an end of the control link arm to a vehicle structure or axle component. The bushing assembly is positioned within the tubular portion such that radial stiffness is distributed away from a center of the tubular portion. This configuration provides a high conical rate and provides auxiliary roll stiffness such that a sway bar is not required.

Abstract: A leaf spring for a vehicle suspension is formed from a composite material and includes at least one spring end with a curved recess. A bushing assembly is attached to the curved recess. The bushing assembly includes a mounting component and a bushing that is attached to the mounting component such that the leaf spring can be pivotally attached to a vehicle frame. The mounting component is formed around an outer periphery of the curved recess to secure the mounting component to the leaf spring such that the bushing is received within the curved recess.

Abstract: An axle system includes an axle shaft offset located within an axle center beam housing. The axle shaft is located in a recess in a top wall of the axle center beam shaped with slopes to maximize clearance to the bottom of the vehicle floor panels. The pneumatic brake cylinders define a cylinder axis angled within an angular range from a generally vertical orientation for enhanced packaging.

Abstract: A drive unit for a vehicle wheel assembly includes an input gear set driven by an electric motor, a planetary gear set driven by the input gear set, and an output shaft driven by the planetary gear set. An adapter is used to attach a wheel rim and a brake component for rotation with the output shaft, which is rotatably supported by a wheel bearing. The input gear set and the planetary gear set are positioned outboard of the electric motor and inboard of the brake component. The brake component can be easily removed without requiring removal of the planetary gear set or any wheel bearings. Only the wheel rim and the adapter have to be removed in order to remove the brake component.

Abstract: A vehicle suspension includes trailing arm assemblies that have one end pivotally mounted to a first suspension rail, an opposite end with an air spring support formed with the trailing arm, and an axle mount portion that is mounted to an axle beam. A Panhard arm provides lateral stiffness and includes a first pivotal connection to the trailing arm and a second pivotal connection to a second suspension rail laterally spaced from the first suspension rail.

Abstract: An electric drive axle includes a pair of center mounted electric motors that independently drive a pair of laterally spaced wheels. The electric drive axle includes an axle housing assembly that extends between the pair of laterally spaced wheels. Both center mounted electric motors preferably do not include connections to a chassis and are solely supported by the axle housing assembly near a vehicle centerline.

Abstract: A wheel end assembly includes an output shaft that is directly mountable to a wheel adapter to drive a vehicle wheel. A gear assembly is coupled to the output shaft to transfer driving force from an input to the output shaft. The gear assembly includes an output gear that is directly coupled to the output shaft. Thus, the wheel adapter and output gear are both supported directly on the output shaft. The gear assembly and output shaft are substantially enclosed within a housing that is mounted to a non-rotating vehicle component. The output shaft is solely supported by a pair of bearings for rotation relative to the housing. The bearings are installed for direct engagement with the output shaft and housing.