A front axle assembly with an axle housing that has first and second housing halves that each include a main housing portion, a tubular portion and a steering yoke. The main housing portion defines a cavity that houses at least a portion of a speed differentiation mechanism. The tubular portions are fixedly coupled to an associated one of the main housing portions and extend between the main housing portion and an associated one of the steering yokes. Each steering yoke is fixedly coupled to an associated tubular portion. An annular joint structure is formed where the first and second first housing halves are coupled to one another. The annular joint structure is formed about the rotary axis such that one of the first and second housing halves is inserted into the other one of the first and second housing halves along an insertion axis that is coincident with the rotary axis.

An axle assembly with a housing, an annular gear, a bearing, a differential, and a pair of output shafts. The housing has an annular hub. The annular gear is received in the housing. The bearing, which is a four-point angular contact bearing, supports the gear for rotation about an axis relative to the housing and has an inner bearing race, which is mounted on the annular hub, and an outer bearing race that is fixedly coupled to the annular gear. The differential is received in the housing and includes an input member, which is coupled to the annular gear for rotation therewith, and a pair of output members that are rotatable relative to the input member about the output axis. Each of the output shafts is coupled to an associated one of the output members for rotation therewith. One of the output shafts extends through the annular hub.

An axle assembly with a housing, an annular gear, a bearing, a differential, and a pair of output shafts. The housing has an annular hub. The annular gear is received in the housing. The bearing, which is a four-point angular contact bearing, supports the gear for rotation about an axis relative to the housing and has an inner bearing race, which is mounted on the annular hub, and an outer bearing race that is fixedly coupled to the annular gear. The differential is received in the housing and includes an input member, which is coupled to the annular gear for rotation therewith, and a pair of output members that are rotatable relative to the input member about the output axis. Each of the output shafts is coupled to an associated one of the output members for rotation therewith. One of the output shafts extends through the annular hub.

An apparatus and methods are provided for a portal spindle assembly for a vehicle front suspension. The portal spindle assembly comprises a spindle portion that is rotatably coupled with upper and lower connecting arms. A leading-edge portion is rotatably coupled with a steering rod-end joint, such that moving the steering rod-end joint rotates the spindle assembly with respect to the upper and lower connecting arms. An inboard case and an outboard case support a pinion gear assembly that is meshed with an output gear assembly for communicating torque from a constant velocity joint to a front wheel coupled to the output gear assembly. The pinion gear assembly is aligned along a pinion axis disposed at an angle with respect to a hub axis of the output gear assembly. The angle facilitates a suspension geometry that provides a camber change of the front wheel that eliminates a change in track width.

An electric beam axle has a central housing around the electric motor and the differential gearing. Tubes are attached to each side of the central housing around the axle shafts. The tubes are attached to the central housing using butt welds. A portion of the central housing near the weld is designed to minimize stress concentrations. In particular, the region immediately adjacent to the weld has a constant thickness. Between the constant thickness region and the main part of the central housing is a tapered region.

An electric beam axle has a central housing around the electric motor and the differential gearing. Tubes are attached to each side of the central housing around the axle shafts. The tubes are attached to the central housing using butt welds. A portion of the central housing near the weld is designed to minimize stress concentrations. In particular, the region immediately adjacent to the weld has a constant thickness. Between the constant thickness region and the main part of the central housing is a tapered region.

Systems are provided for an axle arm including a lubricant reservoir and a driveshaft. In one example, system may include a lubricant reservoir of an axle arm comprising a fill line at an edge of a driveshaft, wherein a central axis of the lubricant reservoir is misaligned with a central axis of the driveshaft.

Systems are provided for an axle arm including a lubricant reservoir and a driveshaft. In one example, system may include a lubricant reservoir of an axle arm comprising a fill line at an edge of a driveshaft, wherein a central axis of the lubricant reservoir is misaligned with a central axis of the driveshaft.

An axle for heavy-duty vehicles, the axle comprising first and second grooves formed about the axle. The first and second grooves include a cross-sectional geometry that forms integrated annular fixturing locations about the axle for selectively mounting a component of a braking system.

An electric drive axle includes an idler shaft having an input gear and an output gear rotatably mounted thereon. The output gear includes a plurality of first clutch teeth formed thereon. A clutch assembly is also disposed on the idler shaft between the input and output gears. The clutch assembly includes a clutch member having a plurality of second clutch teeth formed thereon, wherein the second clutch teeth are selectively engageable with the first clutch teeth of the output gear.