Anchor bracket for use in a disc brake assembly and method for making the same

A method for producing a disc brake assembly, the method comprising:

• (a) providing an as cast anchor bracket having two extending arms;
• each of the arms including an inboard end and an outboard end connected by a bridge portion;
• each of the inboard ends defining an inboard channel;
• each of the outboard ends defining an outboard channel;
• each of the bridge portions including a guide pin hole;
• the inboard ends, outboard send, and bridge portions defining a rotor channel adapted to accommodate a rotor;
• one of the inboard ends and outboard ends including a mounting opening adapted to receive a retainer to secure the anchor bracket relative to a vehicle component;
• at least one of the inboard ends and the outboard ends of the arms being interconnected by a tie bar;
• (b) subsequent to step (a), machining selected surfaces of the as cast anchor bracket, including:
• (1) machining for brake shoe assembly clearances only the faces of each of the inboard channels and the faces of the outboard channels of the cast anchor bracket;
• and
• (2) machining for rotor clearance only a portion of the two arms facing the rotor channel and not a portion of an underside of the bridge facing the rotor channel;
• (c) subsequent to step (b), installing a clip in the inboard channel of each arm and the outboard channel of each arm;
• (d) subsequent to step (c), providing an inboard brake shoe assembly and an outboard brake shoe assembly and installing the inboard brake shoe assembly and the outboard brake shoe assembly such that the inboard brake shoe assembly and the outboard brake shoe assembly are supported for sliding movement relative to the clips;
• and
• (e) subsequent to step (d), providing a caliper assembly and securing the caliper assembly to the anchor brake for slidable movement relative thereto.

An anchor bracket adapted for use in a disc brake assembly, the disc brake assembly including four clips fixedly attached to the anchor bracket for supporting a pair of brake show assemblies, the anchor bracket comprising:

• a cast anchor bracket having two extending arms, each of the arms including an inboard end and an outboard end connected by a bridge portion, each of the inboard ends defining an inboard channel, each of the outboard ends defining an outboard channel, each of the bridge portions including a guide pin hole,
• the inboard ends, outboard ends, and bridge portions defining a rotor channel adapted to accommodate a rotor, one of the inboard ends and outboard ends including a mounting opening adapted to receive a retainer to secure the anchor bracket relative to a vehicle component, at least one of the inboard ends and the outboard ends of the arms being interconnected by a tie bar;
• wherein selected surfaces of the anchor bracket are machined, including:
• for brake shoe assembly clearances, only the faces of the inboard channels and the faces of the outboard channels;
• and
• for rotor clearance, only portions of the two arms facing the rotor channel, and not a portion of an underside of the bridge portions facing the rotor channel.