Abstract: A steering knuckle assembly for a motor vehicle. The steering knuckle assembly includes a stamped knuckle housing which provides attachment points for various suspension components, including a steering arm. The knuckle housing is formed with a pair of generally spaced apart, opposing side walls being connected by an integral transverse wall. Opposite of the transverse wall, a steering arm link bridges the gap between the side walls thereby increasing the resistance of the knuckle housing to bending and torsional loads. Extending off of one end the steering arm link is a mounting arm which provides an attachment point for the steering arm.

Abstract: A steering knuckle attachment configuration for mounting with motor vehicle suspension and steering components is provided in a one piece steering knuckle housing. The lower end of the housing includes a flat major face to which a bearing carrier or torque plate may be mounted. The knuckle housing has both an upper end and a lower end, one of which includes an integrally formed open ended channel that is also open on one side. The channel is adapted to receive in its open end an attachment post projecting a suspension component. The post is secured within the channel by a transversely inserted fastener which engages the post member in an interference relationship.

Abstract: An improved apparatus and method for fabricating a composite disc brake rotor. In accordance with this invention, a composite rotor having a stamped center section and a cast or forged braking face portion is mounted onto a press which produces a central axially deflected "bubble" of metal. The formation of such a bubble causes radially inward straining of the material defining the rotor center section which has been found to substantially reduce surface waviness and imperfections in the surface. Such improvements in flatness of the rotor center section provide accurate positioning of the rotor braking when mounted on the vehicle for improved brake performance and life. Following the step of producing the center bubble, a subsequent operation is used to blank out a center mounting hole and clearance holes for wheel mounting studs.

Abstract: An improved steering knuckle assembly of the type including a stamped knuckle housing portion. In accordance with this invention, the conventional means for attaching suspension components to the knuckle which includes a tapered stud and correspondingly tapered bore within the knuckle are eliminated. Instead, the knuckle housing features a bore which is surrounded by a hemispherical seat region. The protruding stud of the ball joint or steering link extends through the bore and includes features which conform to the shape of both sides of the hemispherical seat to clampingly engage the suspension component to the steering knuckle housing. Another feature according to this invention is a steering knuckle configuration which eliminates the conventional protruding arm necessary for attachment to a steering link. A modified steering link is provided having a protruding stud which attaches directly to the concave-shaped steering knuckle housing.

Abstract: An improved steering knuckle assembly is described which is made by combining a bearing carrier component preferably formed by casting or forging processes to a steering knuckle housing preferably made from stamped sheet metal. This composite structure replaces existing integral cast or forged units. By replacing a portion of a conventional cast or forge steering knuckle with stamped sheet metal components, significant weight savings are achieved. Further, production tooling costs are further reduced due to the comparable cost advantage of metal stamping tools versus casting, forging, and machining tooling. In addition to a cartridge wheel bearing assembly within the steering knuckle assembly, a redundant bearing mounting is provided when this mechanical trapping is coupled with an interference fit between the bearing carrier internal bore and the cartridge wheel bearing assembly. The stamped steering knuckle housing has several suspension fastening bushings, welded or otherwise, attached thereto.