Abstract: A steering knuckle assembly provides a tapered roller bearing on the bottom and a needle bearing on the top of a king pin. A spring cap preloads the tapered roller bearing. The king pin includes a step on the upper portion to transfer the spring cap preload force to the top of an axle beam.

Abstract: A transfer case assembly includes an input gear, an idler gear, and an output gear. The idler gear is mounted on an idler shaft, which is rotatably supported by a bearing retained within a carrier. The carrier fits within an arcuate slot. The arcuate slot defines a multiple of idler shaft predetermined mounting locations. Each of the idler shaft predetermined mounting locations are equidistant from the third axis, and vary in distance from the first axis. For each of the idler shaft predetermined mounting locations a gear, of a predetermined size is provided to achieve a proper gear mesh for the desired gear ratio.

Abstract: A seal assembly includes a protective shield, a seal and a seal wiper. A garter spring is located about the outer perimeter of the seal to provide a constricting force around the seal to assure that the lips contact the seal wiper even after deformation and wear of the seal assembly. Another seal assembly includes an integrally shielded seal manufactured of a non-metallic material.

Abstract: An independent suspension undercarriage module includes a first subframe segment and a second subframe segment. The subframe is manufactured of a composite material to provide a truss-like structural unibody which is mounted as a unit to the underside of a low floor vehicle through a plurality of resilient dampers. Passengers are thereby provided with a secondary vibration isolation structure separate from the suspension systems which filter out high frequency content generated by the suspension systems.

Abstract: A wheel end assembly for a mass transit vehicle includes an output shaft mounted to a wheel hub for driving a vehicle wheel. The output shaft is driven by a gear assembly mounted within a gear housing and operably coupled to an input shaft. The gear assembly includes an input gear driven by the input shaft, a first reduction gear in meshing engagement with the input gear, a second reduction gear operably coupled to the first reduction gear for rotation therewith, and an output gear in meshing engagement with the second reduction gear. The first and second reduction gears are supported on a common shaft that is positioned between the input and output shafts. The input gear and first reduction gear are positioned outboard from the output gear and associated bearings. This double reduction configuration allows vehicle aisle width to be maintained while providing a deeper drop allowing the vehicle floor to be lowered to a position closer to the ground.

Abstract: A first and second hub assembly supported by an independent suspension system allows the independent articulation of each hub assembly. An input gear box includes a reduction gear set that drives a reduction gear set at each hub assembly. The input gear box is mounted offset from the first axis and the vehicle longitudinal axis to simultaneously drive both hub assemblies to allow a lowered vehicle floor profile.

Abstract: A compound gear assembly includes two gears, each gear respectively including interlocking features, which may be complimentary arcuate sections, for transferring torque between the gears. A clearance between the respective arcuate sections permits the gears to move radially relative to one another, which ensures that the gears mesh in a desired manner with the gears to which they are coupled. A retainer is inserted into an annular groove located circumferentially about the respective arcuate sections, which secures one gear to another.

Abstract: An axle system includes an axle lubrication level within an axle housing which is lower than a wheel end lubrication level within the wheel end assemblies. An opening through the wheel end assembly housing provides a fluid communication path between the wheel end assembly and the axle housing. A differential assembly rotates adjacent an opening such that lubrication at the wheel end lubrication level is rotated into the opening. The lubricant within the wheel end assemblies is maintained at the wheel end lubrication level. The shaft enters the wheel end assembly housing through a shaft opening which provides a communication path for the lubricant from the wheel end assembly back into the axle housing.

Abstract: A brake assembly is provided including a hub assembly having a barrel portion and a flange extending radially outwardly from the barrel portion. The flange includes an outer circumference, and a plurality of studs are arranged circumferentially about the flange inboard of the outer circumference. A brake drum includes a generally annular mounting portion includes a plurality of mounting holes spaced circumferentially thereabout with the plurality of studs disposed within the plurality of mounting holes. A brake drum pilot surface engages the outer circumference of the hub flange and includes a plurality of relief pockets aligned with the plurality of studs. The studs generate a deformed area in the outer circumference of the hub flange aligned with the stud. The deformed areas are received in the relief pockets so that deformation of the outer circumference of the hub flange does not interfere with properly piloting of the brake drum onto the hub assembly.

Abstract: A steering knuckle assembly provides a tapered roller bearing on the bottom and a needle bearing on the top of a king pin. A spring cap preloads the tapered roller bearing. The king pin includes a step on the upper portion to transfer the spring cap preload force to the top of an axle beam.

Abstract: An axle system includes an axle lubrication level within an axle housing which is lower than a wheel end lubrication level within the wheel end assemblies. An opening through the wheel end assembly housing provides a fluid communication path between the wheel end assembly and the axle housing. A differential assembly rotates adjacent an opening such that lubrication at the wheel end lubrication level is rotated into the opening. The lubricant within the wheel end assemblies is maintained at the wheel end lubrication level. The shaft enters the wheel end assembly housing through a shaft opening which provides a communication path for the lubricant from the wheel end assembly back into the axle housing.

Abstract: A compound gear assembly includes two gears, each gear respectively including interlocking features, which may be complimentary arcuate sections, for transferring torque between the gears. A clearance between the respective arcuate sections permits the gears to move radially relative to one another, which ensures that the gears mesh in a desired manner with the gears to which they are coupled. A snap ring is inserted into an annular groove located circumferentially about the respective arcuate sections, which secures one gear to another.

Abstract: A brake assembly is provided including a hub assembly having a barrel portion and a flange extending radially outwardly from the barrel portion. The flange includes an outer circumference, and a plurality of studs are arranged circumferentially about the flange inboard of the outer circumference. A brake drum includes a generally annular mounting portion includes a plurality of mounting holes spaced circumferentially thereabout with the plurality of studs disposed within the plurality of mounting holes. A brake drum pilot surface engages the outer circumference of the hub flange and includes a plurality of relief pockets aligned with the plurality of studs. The studs generate a deformed area in the outer circumference of the hub flange aligned with the stud. The deformed areas are received in the relief pockets so that deformation of the outer circumference of the hub flange does not interfere with properly piloting of the brake drum onto the hub assembly.

Abstract: A suspension system includes a swing arm which pivots about a pivot axis. A hub assembly, hub gear box and input gear box are mounted to an independently pivoting swing arm. The pivot axis is located closer to the ground than a rotational axis defined by the hub assemblies and the input gear box. A coupling extends from the input gear box to receive an input driveline from a drive source such as vehicle engine. The coupling is located proximate the pivot axis to minimize relative movement during articulation of the swing arm. An axle housing extends between the input gear box and an opposite hub gear box to support a drive shaft and serves as a torsion bar.

Abstract: An axle assembly is provided that includes a tubular member having an outer wall and an interior cavity. The other wall includes a first interlocking feature. An axle component mounting member, such as a bearing shoulder sleeve and/or a brake flange, is arranged on a portion of the outer wall. The mounting member includes a second interlocking feature coacting with the first interlocking feature to affix the mounting member and tubular member to one anther. The axle assembly may be formed by arranging the axle mounting member into a die assembly. A tubular member may be arranged in the die assembly within an opening in the mounting member. A hydroforming process may be employed to pressurize a cavity within the tubular member. A portion of the tubular member is deformed into engagement with the mounting member to affix the mounting member to the tubular member.

Abstract: A front axle beam assembly is provided comprising a center beam portion having opposing first connections. Knuckles having second connections are secured to the first connections of the beam preferably by threaded fasteners. A spindle is pivotally supported on each knuckle by king pins. The center portion of the axle may be constructed from a material different than that of the knuckles. Moreover, the knuckles may be formed by a different process than that of the center axle portion. For example, the center portion may be constructed from an aluminum casting while the knuckles may be constructed from a steel forging. Different axle center portions may be selected depending on the desired track and suspension attachment points. Similarly, the knuckles may be selected to provide desired suspension attachment points for linkages, airbags, and/or leaf springs. The knuckles may be selected to achieve a desired axle beam drop.

Abstract: A disc brake system includes a hub having a plurality of extensions and a multi-portion rotor which can be separated without disturbing the hub, bearing or other axle assemblies. The extensions engage the brake rotor assembly to transfer braking torque between the rotor assembly and the hub. Each extension is received between abutments which extend from an inner surface of the brake rotor portions opposite the engagement surface which contacts a brake pad. Threaded fasteners and hollow concentric bushings are mounted transverse the parting line to mount the brake rotor portions together. Another disc brake assembly includes four extensions arranged in a cruciform pattern about the hub. An offset parting line allows for an angled approach of the joint between the assembled rotor portions as it rotates into brake pads to provide less wear from any potential joint mismatch.

Abstract: A drive axle assembly for a low floor vehicle utilizes a single input gear assembly to drive a pair of laterally spaced wheel ends. The input gear assembly is positioned next to one of the wheel ends so that the vehicle floor can be lowered to facilitate passenger access to the vehicle. Each wheel end includes a gear reduction assembly with a ring gear rotatably mounted within a gear housing. A drive gear is operatively coupled to the input gear assembly and is in meshing engagement with the ring gear. The gear reduction assembly also includes an output or driven gear, which is larger than the drive gear, to provide the desired gear reduction. The driven gear is also in meshing engagement with the ring gear. A pair of idler gears is rotatably mounted within the gear housing and are in meshing engagement with both the drive and driven gear. The idler gears and drive gear do not have a common centerline.

Abstract: An independent suspension module includes a plurality of control members that are positioned to allow the suspension module to be used on low profile vehicles such as low floor buses. The suspension module includes a plurality of control members that couple a support member to the vehicle structure so that the suspension module is appropriately supported relative to the vehicle. The control members include a first end supported near a vertical portion of the lower surface of the vehicle. A second end of at least some of the control members are supported on the support member of the suspension module such that the second ends are positioned between the inboard and outboard sides of the wheels.

Abstract: An axle assembly is provided that includes a tubular member having an outer wall and an interior cavity. The other wall includes a first interlocking feature. An axle component mounting member, such as a bearing shoulder sleeve and/or a brake flange, is arranged on a portion of the outer wall. The mounting member includes a second interlocking feature coacting with the first interlocking feature to affix the mounting member and tubular member to one anther. The axle assembly may be formed by arranging the axle mounting member into a die assembly. A tubular member may be arranged in the die assembly within an opening in the mounting member. A hydroforming process may be employed to pressurize a cavity within the tubular member. A portion of the tubular member is deformed into engagement with the mounting member to affix the mounting member to the tubular member.