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 wheel hub assembly includes a first bearing assembly, a wheel hub, a grease retainer, and a second bearing assembly mounted on a spindle. The grease retainer extends between and in engagement with the first bearing cup, and the second bearing cup. The grease retainer is formed of a resilient material, to maintain the retainer against the bearing cups such that the required grease fill is reduced and prevents grease from escaping the bearing assemblies.

Abstract: A tubular axle beam with variable wall thickness for a vehicle is provided including a first beam portion extending longitudinally between first ends and including spaced apart first longitudinal edges. A second beam portion extends longitudinally between second ends and includes spaced apart second longitudinal edges. Weld beads secure the first longitudinal edges to the second longitudinal edges to define a cavity between the beam portions with the first and second ends arranged adjacent to one another. Preferably, the tubular axle beam is constructed by stamping a first blank to form a first half of the beam, and a second blank is stamped to form a second half of the beam. The first and second portions are welded to one another to define a cavity between the portions. In another embodiment of the invention, a tubular axle beam includes a hollow beam extending longitudinally between opposing ends.

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.