METHODS AND APPARATUS FOR MOVING THE FRONT WHEELS OF A VEHICLE FORWARD

Abstract

The present invention provides embodiments of modified upper and lower control arms for attachment to the steering knuckle that came with the vehicle, or for attachment to a modified steering knuckle of an embodiment of the invention, such that the steering knuckle, and in particular the wheel hub opening of the steering knuckle, are located at positions that are closer to the front of the vehicle than the positions provided by the control arms that came with the vehicle.

The forward position of the wheel hub relative to the position provided by the factory or stock control arms moves the wheel and tire forward by the same distance, thereby allowing much larger wheels and tires to be mounted on the vehicle which do not rub against or interfere with the wheel well, fender or body mount, thereby increasing the approach angle of the vehicle for use in off-road climbing.

Claims

1-26. (canceled)

27. An apparatus for mounting a steering knuckle on a vehicle such that a hub opening of the steering knuckle is at a position that is closer to a front of the vehicle than a factory position for said hub opening comprising: a. an upper steering knuckle control arm comprising a first body having a first pair of mounts at one end thereof for engagement with a vehicle frame, and a first ball joint mount at an opposite end thereof for engagement with a first ball joint of said steering knuckle, and b. a lower steering knuckle control arm comprising a second body having a second pair of mounts at one end thereof for engagement with the vehicle frame, and a second ball joint mount at an opposite end thereof for engagement with a second ball joint of said steering knuckle, wherein the first and second ball joint mounts are located at least one inch (1″) closer to the front of the vehicle than corresponding positions of stock first and second ball joint mounts of stock upper and lower steering knuckle control arms replaced by said apparatus.

28. The apparatus of claim 27 wherein when the steering knuckle is mounted to the vehicle using said upper and lower control arms, the hub opening is positioned at least one inch (1″) closer to the front of the vehicle than when mounted using said replaced stock upper and lower control arms.

29. The apparatus of claim 27 wherein at least one of said first and second ball joints is a horizontal ball joint.

30. The apparatus of claim 27 wherein at least one of said first and second ball joints is a uni-ball.

31. The apparatus of claim 27 wherein at least one of said upper control arm and said lower control arm is longer than the replaced stock control arm.

32. The apparatus of claim 27 wherein the first and second ball joint mounts are closer to the front of the vehicle by an approximately equal distance.

33. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of between at least one inch (1″) and about four inches (4″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of between about one inch (1″) and about four inches (4″).

34. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of between at least one inch (1″) and about two and one half inches (2.5″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of between about one inch (1″) and about two and one half inches (2.5″).

35. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of between at least one and one half inches (1½″) and about three inches (3″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of between at least one and one half inches (1½″) and about three inches (3″).

36. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of about one inch (1″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about one inch (1″).

37. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of about two inches (2″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about two inches (2″).

38. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of about two and one half inches (2.5″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about two and one half inches (2.5″).

39. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of at least two inches (2″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of at least two inches (2″).

40. The apparatus of claim 27 wherein the position of said first ball joint mount of said upper control arm is closer to the front of the vehicle by an amount of at least two and one half inches (2.5″), and the position of said second ball joint mount of said lower control arm is closer to the front of the vehicle by an amount at least two and one-half inches (2.5″).

41. A method for moving a steering knuckle of a vehicle forward such that a hub opening of the steering knuckle is at a position that is closer to a front of the vehicle than a factory position for said hub comprising the steps of: a. removing a wheel, hub and steering knuckle from the vehicle; b. removing upper and lower steering knuckle control arms from the vehicle; c. installing an upper steering knuckle control arm on said vehicle, said upper control arm having a body with a first pair of mounts at one end thereof for engagement with a vehicle frame, and a first ball joint mount at an opposite end thereof, the first ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a first ball joint mount of the upper steering knuckle control arm that was removed from the vehicle; d. installing a lower steering knuckle control arm on said vehicle, said lower control arm having a body with a second pair of mounts at one end thereof for engagement with the vehicle frame, and a second ball joint mount at an opposite end thereof, the second pivotal ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a second ball joint mount of the lower steering knuckle control arm that was removed from the vehicle; e. attaching the steering knuckle to the installed upper and lower control arms; and f. attaching the hub, wheel and tire.

42. The method of claim 41 comprising the additional step of removing a wheel axle from the vehicle and replacing said axle with a longer wheel axle.

43. The method of claim 41 comprising the additional step of removing a steering control arm from the vehicle and replacing said steering control arm with a longer steering control arm.

44. The method of claim 41 comprising the additional step of removing a shock absorber from the vehicle and replacing said shock absorber with a longer shock absorber.

45. An apparatus for mounting a steering knuckle on a vehicle comprising: a. a steering knuckle; b. an upper steering knuckle control arm comprising a first body having a first pair of mounts at one end thereof for engagement with a vehicle frame and a first ball joint mount at an opposite end thereof for engagement with a first upper ball joint of said steering knuckle, and c. a lower steering knuckle control arm comprising a second body having a second pair of mounts at one end thereof for engagement with the vehicle frame, and a second ball joint mount at an opposite end thereof for engagement with a lower ball joint of said steering knuckle, wherein said first and second ball joint mounts are located at positions that are at least one inch (1″) closer to a front of the vehicle than corresponding positions of stock upper and lower control arms replaced by said apparatus.

46. The apparatus of claim 45 wherein the steering knuckle further comprises a hub opening, such that when the steering knuckle is mounted to the vehicle using said upper and lower control arms, the hub opening is positioned at least one inch (1″) closer to the front of the vehicle than when mounted using said replaced stock upper and lower control arms.

47. A method for replacing a steering knuckle of a vehicle such that a hub opening of the replacement steering knuckle is at a position that is closer to a front of the vehicle than a stock position for a hub of the replaced steering knuckle comprising the steps of: a. removing a wheel, hub and steering knuckle from the vehicle; b. removing upper and lower steering knuckle control arms from the vehicle; c. installing an upper steering knuckle control arm on said vehicle, said upper control arm having a body with a first pair of mounts at one end thereof for engagement with a vehicle frame, and a first ball joint mount at an opposite end thereof, the first ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a first ball joint mount of the upper steering knuckle control arm that was removed from the vehicle; d. installing a lower steering knuckle control arm on said vehicle, said lower control arm having a body with a second pair of mounts at one end thereof for engagement with the vehicle frame, and a second ball joint mount at an opposite end thereof, the second ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a second ball joint mount of the lower steering knuckle control arm that was removed from the vehicle; e. attaching a replacement steering knuckle to the installed upper and lower control arms; and f. attaching the hub, wheel and tire.

48. An apparatus for mounting a steering knuckle on a vehicle such that a hub opening of the steering knuckle is at a position that is closer to a front of the vehicle than a factory position for said hub opening comprising a lower steering knuckle control arm comprising a body having a pair of mounts at one end thereof for engagement with a vehicle frame, and a ball joint mount at an opposite end thereof for engagement with a ball joint of said steering knuckle, wherein the ball joint mount is located at least one inch (1″) closer to the front of the vehicle than a corresponding position of a stock ball joint mount of a stock lower steering knuckle control arm replaced by said apparatus.

49. The apparatus of claim 48 wherein said ball joint is a horizontal ball joint.

50. The apparatus of claim 48 wherein said ball joint is a uni-ball.

51. The apparatus of claim 48 further comprising a steering knuckle having a lower ball joint mount for engagement with said ball joint.

52. The apparatus of claim 48 wherein said lower control arm is longer than the replaced stock lower control arm.

53. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of between at least one inch (1″) and about four inches (4″).

54. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of between at least one inch (1″) and about two and one half inches (2.5″).

55. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about one inch (1″).

56. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about two inches (2″).

57. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of about two and one half inches (2.5″).

58. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of at least one inch (1″).

59. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount of at least two inches (2″).

60. The apparatus of claim 48 wherein the position of said ball joint mount of said lower control arm is closer to the front of the vehicle by an amount at least two and one-half inches (2.5″).

61. A method for moving a steering knuckle of a vehicle forward such that a hub opening of the steering knuckle is at a position that is closer to a front of the vehicle than a factory position for said hub comprising the steps of: a. removing a wheel, hub and steering knuckle from the vehicle; b. removing a lower steering knuckle control arm from the vehicle; c. installing a lower steering knuckle control arm on said vehicle, said lower control arm having a body with a pair of mounts at one end thereof for engagement with a vehicle frame, and a ball joint mount at an opposite end thereof, the ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a ball joint mount of the lower steering knuckle control arm that was removed from the vehicle; d. attaching the steering knuckle to an upper control arm and to the installed lower control arm; and e. attaching the hub, wheel and tire.

62. The method of claim 61 wherein the step of attaching the steering knuckle comprises the steps of engaging a first ball joint with a first ball joint mount on an upper control arm and with an upper ball joint mount on the steering knuckle, and engaging a second ball joint with the ball joint mount on said lower control arm and with a lower ball joint mount on the steering knuckle.

63. The method of claim 61 wherein the step of attaching the steering knuckle comprises the steps of removing studs of upper and lower ball joints of the steering knuckle, passing a first bolt through an opening in an upper uni-ball on an upper control arm, attaching the first bolt to the steering knuckle where an upper stud had previously been attached, passing a second bolt through an opening in a lower uni-ball on said lower control arm, and attaching the second bolt to the steering knuckle where a lower stud had previously been attached.

64. The method of claim 61 comprising the additional step of removing a wheel axle from the vehicle and replacing said axle with a longer wheel axle.

65. The method of claim 61 comprising the additional step of removing a steering control arm from the vehicle and replacing said steering control arm with a longer steering control arm.

66. The method of claim 61 comprising the additional step of removing a shock absorber from the vehicle and replacing said shock absorber with a longer shock absorber.

67. A method for replacing a steering knuckle of a vehicle such that a hub opening of the replacement steering knuckle is at a position that is closer to a front of the vehicle than a stock position for the hub of the replaced steering knuckle comprising the steps of: a. removing a wheel, hub and steering knuckle from the vehicle; b. removing a lower steering knuckle control arm from the vehicle; c. installing a lower steering knuckle control arm on said vehicle, said lower control arm having a body with a pair of mounts at one end thereof for engagement with a vehicle frame, and a ball joint mount at an opposite end thereof, the ball joint mount being located at a position that is at least one inch (1″) closer to the front of the vehicle than a corresponding position of a ball joint mount of the lower steering knuckle control arm that was removed from the vehicle; d. attaching a replacement steering knuckle to an upper control arm and to the installed lower control arm; and f. attaching the hub, wheel and tire.

68. An apparatus for mounting a steering knuckle on a vehicle having a frame comprising a body having a pair of mounts at one end thereof for engagement with the vehicle frame, and a ball joint mount at an opposite end thereof for engagement with a lower ball joint of said steering knuckle, wherein said ball joint mount is located at a position that is at least one inch (1″) closer to a front of the vehicle than a corresponding position of a stock lower control arm replaced by said apparatus.

69. The apparatus of claim 47 wherein the steering knuckle further comprises a hub opening, such that when the steering knuckle is mounted to the vehicle using said lower control arm, the hub opening is positioned at least one inch (1″) closer to the front of the vehicle than when mounted using said replaced stock lower control arm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1 is an environmental view showing upper and lower control arms of an embodiment of the present invention installed on a vehicle.

[0042] FIG. 2 is a side view of an embodiment of the control arms of the present invention showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle (spindle).

[0043] FIG. 3A is a side view of a set of upper and lower factory control arms showing them mounted to an exemplary vehicle frame, with a phantom line showing the position of the lower ball joint of the steering knuckle.

[0044] FIG. 3B is a side view of an embodiment of the upper and lower control arms of the present invention showing them mounted to an exemplary vehicle frame, aligned with the view of FIG. 3A, with a second phantom line showing the forward position of the lower ball joint of the steering knuckle.

[0045] FIG. 4A is a side view of a set of upper and lower factory control arms showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle, with a phantom line showing the position of the lower ball joint and wheel hub opening of the steering knuckle.

[0046] FIG. 4B is a side view of an embodiment of the upper and lower control arms of the present invention showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle, aligned with the view of FIG. 4A, with a second phantom line showing the forward position of the lower ball joint and wheel hub opening of the steering knuckle.

[0047] FIG. 5A is a side view of a lower factory control arm with a phantom line showing the position of the lower ball joint of the steering knuckle.

[0048] FIG. 5B is a side view of an embodiment of a lower control arm of an embodiment of the present invention with a second phantom line showing the forward position of the lower ball joint relative to the lower factory control arm of FIG. 5A.

[0049] FIG. 6 is a side view of an alternative embodiment of the control arms of the present invention showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle.

[0050] FIG. 7A is a side view of a set of upper and lower factory control arms showing them mounted to an exemplary vehicle frame, with a phantom line showing the position of the lower ball joint of the steering knuckle.

[0051] FIG. 7B is a side view of an alternative embodiment of upper and lower control arms of the present invention showing them mounted to an exemplary vehicle frame, aligned with the view of FIG. 7A, with a second phantom line showing the forward position of the lower ball joint of the steering knuckle.

[0052] FIG. 8A is a side view of a set of upper and lower factory control arms showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle, with a phantom line showing the position of the lower ball joint and wheel hub opening of the steering knuckle.

[0053] FIG. 8B is a side view of an alternative embodiment of the upper and lower control arms of the present invention showing them mounted to an exemplary vehicle frame and to an exemplary steering knuckle, aligned with the view of FIG. 8A, with a second phantom line showing the forward position of the lower ball joint and wheel hub opening of the steering knuckle.

[0054] FIG. 9A is a side view of a lower factory control arm with a phantom line showing the position of the lower ball joint of the steering knuckle.

[0055] FIG. 9B is a side view of an alternative embodiment of a lower control arm of the present invention with a second phantom line showing the forward position of the lower ball joint relative to the lower factory control arm of FIG. 9A.

[0056] FIG. 10 is an environmental view showing upper and lower control arms and a steering knuckle of an embodiment of the present invention installed on a vehicle.

[0057] FIG. 11 is a side view of an embodiment of upper and lower control arms and a steering knuckle of the present invention showing them mounted to a vehicle frame.

[0058] FIG. 12A is a side view of a set of upper and lower factory control arms showing them mounted to an exemplary vehicle frame, with a phantom line showing the position of the lower ball joint and wheel hub opening of the factory steering knuckle.

[0059] FIG. 12B is a side view of upper and lower control arms of an embodiment of the present invention showing them mounted to an exemplary vehicle frame, aligned with the view of FIG. 12A, with a second phantom line showing the forward position of the lower ball joint and wheel hub opening of the steering knuckle.

[0060] FIG. 13A is a side view of a set of upper and lower factory control arms and a factory steering knuckle showing them mounted to an exemplary vehicle frame, with a phantom line showing the position of the lower ball joint and wheel hub opening of the steering knuckle.

[0061] FIG. 13B is a side view of an embodiment of upper and lower control arms and a steering knuckle of the present invention showing them mounted to an exemplary vehicle frame, aligned with the view of FIG. 13A, with a second phantom line showing the forward position of the lower ball joint and wheel hub opening of the steering knuckle.

[0062] FIG. 14A is a side view of a lower factory control arm with a phantom line showing the position of the lower ball joint and wheel hub opening of the steering knuckle.

[0063] FIG. 14B is a side view of an embodiment of a lower control arm of an embodiment of the present invention with a second phantom line showing the forward position of the lower ball joint relative to the lower factory control arm of FIG. 14A.

[0064] FIG. 15 is a left side perspective view of an embodiment of the present invention showing embodiments of an upper control arm, a lower control arm and a steering knuckle installed on a vehicle.

[0065] FIG. 16 is right side perspective view of an embodiment of the present invention showing embodiments of an upper control arm, a lower control arm and a steering knuckle installed on a vehicle.

[0066] FIG. 17 is a close up view of an embodiment of a lower control arm of the present invention.

[0067] FIG. 18A is a front perspective view of an embodiment of the invention showing upper and lower control arms connected to an embodiment of a steering knuckle.

[0068] FIG. 18B is a front perspective view of an embodiment of the invention showing upper and lower control arms connected to the vehicle and to an embodiment of a steering knuckle.

[0069] FIG. 19 is a front perspective view of an embodiment of the invention showing upper and lower control arms connected to the vehicle and to an embodiment of a steering knuckle, also disclosing the positions of the steering control arm and wheel axle.

DETAILED DESCRIPTION OF THE DRAWINGS

[0070] Referring to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1 through 5B, it is seen that this illustrated embodiment of the invention includes an upper control arm 21 having a pair of frame mounts 22 and 23 at one end, and a ball joint mount 24 at an opposite end. Mounts 22 and 23 are designed to attach to sub-frame assembly 16 of frame 19. It is to be appreciated that the location of the upper ball joint mount 24 may be forward of the position of the corresponding mount (e.g. upper ball joint mount) 54 of the factory upper control arm, as shown in FIGS. 4A and 4B (see gap “A”). Mount 24 may be a socket for receiving the ball portion 32 of a stud of the upper ball joint of the steering knuckle.

[0071] In the embodiments shown in FIGS. 6 through 9B, ball joint mount 24 includes a uni-ball 41 mounted inside a bearing 42 where the uni-ball has an opening therethrough 44. A bolt 43 is passed through the uni-ball opening 44 such that the combination of the uni-ball and bolt (41, 43) replaces the stud of the upper ball joint of the steering knuckle. It is to be appreciated that the location of the upper ball joint mount 24 may be forward of the position of the corresponding mount (e.g. upper ball joint mount) 54 of the factory upper control arm, as shown in FIGS. 8A and 8B (see gap “A”). In the embodiments shown in FIGS. 10-17 it is seen that upper mount 24 may be provided in the form of a horizontal ball joint mount, which is described more fully with reference to these figures below.

[0072] As noted elsewhere herein, the forward position of the mount 24 may be zero (in which case the lower mount 29 has a forward location and the steering knuckle itself is angled toward the lower mount—see FIG. 10), as little as about one inch (1″) and as much as about four inches (4″) or more, but preferably between one and one-half inches (1.5″) and three inches (3″), and optimally around two and one half inches (2.5″) in order to accommodate the most desirable wheel sizes. The length of upper control arm 21 may also be greater than that of the factory control arm 51 by a range of about one-half inch (½″) to about four inches (4″).

[0073] The illustrated embodiments of the invention also include a lower control arm 26 having a pair of frame mounts 27 and 28 at one end, and a ball joint mount 29 at an opposite end. Mounts 27 and 28 are designed to attach to sub-frame assemblies 17 and 18, respectively, of frame 19. It is to be appreciated that the location of the lower ball joint mount 29 is forward of the position of the corresponding mount (e.g. lower ball joint mount) 59 of the lower factory control arm, as shown in FIGS. 4A and 4B (see gap “A”), such that the wheel hub opening 35 is also forward of its original position. Mount 29 may be a socket for receiving the ball portion of the stud of the lower ball joint of the steering knuckle.

[0074] In the embodiments shown in FIGS. 6 and 8A-8B, mount 29 is in the form of a uni-ball 46 mounted inside a bearing 47 where the uni-ball 46 has an opening therethrough 49 (See FIG. 9B). A bolt 48 is passed through the uni-ball opening 49 such that the combination of the uni-ball and bolt (46, 48) replaces the stud of the lower ball joint of the steering knuckle. It is to be appreciated that the location of the lower mount 29 is forward of the position of the corresponding mount (e.g. lower ball joint mount) 59 of the lower factory control arm, as shown in FIGS. 8A and 8B (see gap “A”). In the embodiments shown in FIGS. 10-17 it is seen that lower mount 29 may be provided in the form of a horizontal ball joint mount, which is described more fully with reference to these figures below.

[0075] As noted elsewhere herein, the forward position of the pivotal mount 29 may be as little as about one inch (1″) and as much as about four inches (4″) or more, but preferably between one and one-half inches (1.5″) and three inches (3″), and optimally around two and one half inches (2.5″) in order to accommodate the most desirable wheel sizes. The length of lower control arm 26 may also be greater than that of the factory control arm 56 by a range of about one-half inch (½″) to about four inches (4″).

[0076] The embodiment of FIGS. 4A-4B illustrates the position of a steering knuckle 31 with wheel hub opening 35 mounted to factory upper and lower control arms (FIG. 4A), and the forward position of the steering knuckle 31 when mounted to the illustrated embodiments of the upper and lower control arms of the present invention (FIG. 4B). In these embodiments, it is seen that the upper ball joint mount 32 of the steering knuckle engages with upper ball joint mount 24 of upper control arm 21, and lower ball joint mount 33 of the steering knuckle engages with lower ball joint mount 29 of lower control arm 26. It is to be appreciated that in alternative embodiments, the stud of the upper ball joint mount of the factory steering knuckle may be removed and replaced with a uni-ball and bolt combination located at the end of the upper control arm; and that the stud of the lower ball joint mount of the factory steering knuckle may be removed and replaced with a uni-ball and bolt combination located at the end of the lower control arm, as shown in FIGS. 8A-8B. In other embodiments, the upper and lower mounts may be provided in the form of horizontal ball joints, as shown in FIGS. 10-17. A first shock absorber mount 38, and an optional second shock absorber mount 39 may also be provided on lower control arm 26.

[0077] FIGS. 8A-8B illustrate the position of a steering knuckle 31 with wheel hub opening 35 mounted to factory upper and lower control arms (FIG. 8A), and the forward position of the steering knuckle 31 when mounted to the illustrated embodiments of the upper and lower control arms of the present invention (FIG. 8B). In these embodiments, it is seen that the stud of the upper ball joint of the steering knuckle has been removed and replaced with a uni-ball and bolt combination (41, 43) which is mounted in bearing 42, with the bolt 43 attached to the steering knuckle where the upper ball joint stud had been previously attached. In these embodiments, it is seen that the stud of the lower ball joint of the steering knuckle has also been removed and replaced with a uni-ball and bolt combination (46, 48) which is mounted in bearing 47, with the bolt 48 attached to the steering knuckle where the lower ball joint stud had been previously attached. A first shock absorber mount 38, and an optional second shock absorber mount 39 may also be provided on lower control arm 26.

[0078] The after-market upper and lower control arms of the embodiments of FIGS. 1-9 of the present invention are designed to replace the factory-supplied control arms, and allow much larger tires to be mounted on the factory steering knuckle without rubbing against or interfering with the wheel well, body mount 13 or fender 14. These embodiments provide greater wheel-travel, suspension articulation, stability, clearance, and a reduction in overall component angles.

[0079] It is to be appreciated that although no replacement of the of factory steering knuckle is needed in many embodiments of the present invention, a custom steering knuckle can be used and attached to alternative embodiments of the control arms of the present invention. For example and without limitation, the control arms of such alternative embodiments may have any suitable joints for connection between such a custom steering knuckle and each control arm, including without limitation a uni-ball, spherical bearing and/or double shear joint.

[0080] In particular, as shown in FIGS. 10-14, it is seen that this illustrated embodiment of the invention includes an upper control arm 61 having a pair of frame mounts 62 and 63 at one end, and a horizontal ball joint mount 64 at an opposite end. Frame mounts 62 and 63 are designed to attach to sub-frame assembly 16 of frame 19. It is to be appreciated that the location of the upper horizontal ball joint mount 64 may be forward of the position of the corresponding mount (e.g. upper ball joint mount) 54 of the factory upper control arm, or it may be at approximately the same place, as shown in FIGS. 11A and 11B. Horizontal ball joint mount 64 may be in the form of a ball with dual shear for engagement with a socket 72 of an upper ball joint mount of the steering knuckle 71.

[0081] As noted elsewhere herein, the forward position of mount 64 may be zero (as shown in FIGS. 11A and 11B) in which case the lower ball joint mount 69 described below will have a forward location, and the steering knuckle itself (71) is angled toward the lower mount. In other embodiments, the forward position of mount 64 may be as little as about one inch (1″) and as much as about four inches (4″) or more, but preferably between one inch (1″) and two and one-half inches (2.5″), and optimally around two and one half inches (2.5″) in order to accommodate the most desirable wheel sizes. The length of upper control arm 61 may also be greater than that of the factory control arm 51 by a range of about one-half inch (½″) to about four inches (4″). The embodiments of the invention illustrated in FIGS. 10-17 also include a lower control arm 66 having a pair of frame mounts 67 and 68 at one end, and lower horizontal ball joint mount 69 at an opposite end. Frame mounts 67 and 68 are designed to attach to sub-frame assemblies 17 and 18, respectively, of frame 19. It is to be appreciated that the location of the lower horizontal ball joint mount 69 is forward of the position of the corresponding mount (e.g. lower ball joint mount) 59 of the lower factory control arm, as shown in FIGS. 12A, 12B and 13A, 13B (see gap “B”), such that the wheel hub opening 75 is also forward of its original position. Horizontal mount 69 may be in the form of a horizontal ball joint with dual shear, for engagement with a socket 73 of a lower ball joint mount of the steering knuckle 71.

[0082] As noted elsewhere herein, the forward position of mount 69 may be as little as about one inch (1″) and as much as about four inches (4″) or more, but preferably between one inch (1″) and two and one-half inches (2.5″), and optimally around two and one half inches (2.5″) in order to accommodate the most desirable tire sizes. The length of lower control arm 66 may also be greater than that of the factory control arm 56 by a range of about one-half inch (½″) to about four inches (4″).

[0083] The embodiment of FIGS. 13A-13B illustrates the position of a factory steering knuckle 31 with wheel hub opening 35 mounted to factory upper and lower control arms (FIG. 13A), and the forward position of the modified steering knuckle 71 and hub opening 75 when mounted to the illustrated embodiments of the upper and lower control arms of the present invention (FIG. 13B). In these embodiments, it is seen that the upper ball joint mount 72 of the steering knuckle 71 engages with horizontal upper ball joint mount 64 of upper control arm 61, and lower ball joint mount 73 of the steering knuckle 71 engages with lower horizontal ball joint mount 69 of lower control arm 66. A first shock absorber mount 78, and an optional second shock absorber mount 79 may also be provided on lower control arm 66.

[0084] Installation of upper and lower control arms of the present invention is accomplished by first removing the wheel, hub and steering knuckle 31 from the vehicle. Then the factory supplied upper and lower control arms are removed. In some embodiments, the axle 86 must also be removed and replaced with a longer axle 87. In some embodiments, the steering control arm 88 must also be removed and replaced with a different steering control arm 89. Then, an upper control arm of the present invention is engaged with the same sub-frame mounts as the upper factory control arm, and a lower control arm of the present invention is engaged with the same sub-frame mounts as the lower factory control arm. To the extent that the wheel hub center is moved forward in any significant amount (e.g. greater than 1-inch), the vehicle steering assembly may need to be repositioned or otherwise modified in order to prevent steering interference.

[0085] In some embodiments, the forwardly positioned upper ball joint mount 24 is engaged with the upper ball joint mount 32 of the steering knuckle 31, and the forwardly positioned lower ball joint mount 29 is engaged with the lower ball joint mount 33 of the steering knuckle. The wheel hub is then attached to the steering knuckle resulting in the wheel hub being located forward from the original wheel position with the factory control arms. A larger wheel and tire may then be placed on the hub.

[0086] In other embodiments, a uni-ball 41 and bearing 42 may be provided at a forwardly-moved end of the upper control arm 21, and a uni-ball 46 and bearing 48 may be provided at a forwardly-moved end of the lower control arm 26. The stud of the upper ball joint of the steering knuckle is removed, a bolt 43 is passed through an opening 44 in the upper uni-ball 41, and the bolt 43 is attached to the steering knuckle where the upper stud had previously been attached. Similarly, the stud of the lower ball joint of the steering knuckle is removed, a bolt 48 is passed through an opening 49 in the lower uni-ball 46, and the bolt 48 is attached to the steering knuckle where the lower stud had previously been attached.

[0087] In further embodiments, the factory supplied upper and lower control arms, and the factory supplied steering knuckle are all removed. Then, an upper control arm of the present invention is engaged with the same sub-frame mounts as the upper factory control arm, and a lower control arm of the present invention is engaged with the same sub-frame mounts as the lower factory control arm. In these embodiments, the factory axle is removed and replaced with a longer axle 87. In these embodiments, the steering control arm 88 must also be removed and replaced with a different steering control arm 89. The (forwardly positioned) upper ball joint mount 64 is engaged with an upper ball joint mount 72 of the steering knuckle 71, and the forwardly positioned lower ball joint mount 69 is engaged with the lower ball joint mount 73 of the steering knuckle 71. To the extent that the wheel hub center is moved forward any significant amount (e.g., greater than 1-inch), the vehicle steering assembly may need to be repositioned or otherwise modified in order to prevent steering interference. The wheel hub is then attached to the steering knuckle resulting in the wheel hub being located forward from the original wheel position with the factory control arms. A larger wheel and tire may then be placed on the hub.

[0088] FIG. 17 shows detail of an embodiment of a lower control arm of the present invention. In these embodiments, the lower control arm 66 is formed in the general shape of the letter “V” having two arms 91 and 92 that are joined at junction 93. The distal ends of these arms 67 and 68 engage the frame supports 17 and 18, respectively, of the vehicle, and the proximate ends are joined at junction 93 which is attached to the lower joint of a steering knuckle 71. The embodiment illustrated in FIG. 17 discloses a horizontal ball joint mount at junction 93 that engages with a horizontal ball joint mount 95 on the steering knuckle 71. However, it is to be appreciated that a vertical ball joint or other junction structure may also be used to connect the lower control arm to the steering knuckle.

[0089] FIGS. 18-20 show front views of an embodiment of the invention having an upper control arm 61, lower control arm 66, and steering knuckle 71. The front view of FIG. 20, shows the position of a lower factory control arm 26 in phantom lines. It is seen that in these embodiments, the lower control arm provides more clearance between the ground and the bottom of the vehicle, more forward caster, an improved camber angle, more room for the wheel axle, and a wider wheel base which provides more overall stability. Embodiments of the lower control arms may include lower plating which helps protect and prevent damage to the brake lines and wheel axle.

[0090] It is to be understood that variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the appended claims when read in light of the foregoing specification.