Modular load distribution unit and assembly method

A load distribution unit for regulating hydraulic pressure within a suspension system, comprising:

• a manifold block with a first cylinder bore that extends longitudinally through said manifold block;
• a first pair of pressure tubes that are at least partially received in said first cylinder bore on opposing sides of said manifold block to define a first pair of opposed cylinders, said first pair of pressure tubes extending longitudinally between a first pair of inboard pressure tube ends and a first pair of outboard pressure tube ends;
• a first piston rod assembly with a first piston rod and a first pair of opposed pistons that are mounted on said first piston rod and are slidingly received within said first pair of opposed cylinders;
• and
• a first integral rod guide and pressure tube coupler that is received in said first cylinder bore in said manifold block and includes a first through-bore,
• wherein said first piston rod extends through said first through-bore in said first integral rod guide and pressure tube coupler in a sliding fit and said first pair of inboard pressure tube ends are received in said first cylinder bore and are retained on opposing ends of said first integral rod guide and pressure tube coupler.

A method of assembling a load distribution unit of a suspension system, the method comprising the steps of:

• inserting a piston rod through a through-bore in an integral rod guide and pressure tube coupler;
• positioning a pair of opposed piston springs in a co-axial arrangement over the first piston rod such that the pair of opposed piston springs abut opposing ends of the integral rod guide and pressure tube coupler;
• mounting a pair of opposed pistons on opposite ends of the piston rod;
• longitudinally sliding a pair of pressure tubes that extend longitudinally between a pair of inboard pressure tube ends and a pair of outboard pressure tube ends over the pair of opposed pistons until the inboard pressure tube ends abut and mate with the opposing ends of the integral rod guide and pressure tube coupler to form a first modular pressure tube and piston subassembly;
• and
• longitudinally sliding the first modular pressure tube and piston subassembly into a first cylinder bore in a manifold block until the integral rod guide and pressure tube coupler is positioned inside the first cylinder bore and at least portions of the pair of pressure tubes extend longitudinally out away from opposing sides of the manifold block.