Method of manufacturing a corner module assembly

A method of manufacturing a corner module assembly wherein first and second faces on a rotor are aligned in perpendicular planes with an axial bore of a knuckle comprising the following steps:

• obtaining knuckle from a source, said knuckle having a first cylindrical body with an axial bore that extends from a first end to a second end and a plurality of projections that radiate from a web adjacent the cylindrical body wherein each projection has an attachment location area through which the knuckle is fixed to another member;
• placing said knuckle in a first fixture and machining said axial bore, a first plurality of surfaces surrounding said first cylindrical body to define a plurality of locator pads and a second plurality of surfaces to define first and second bosses wherein a base for each of the plurality of locator pads is located in a plane that is perpendicular to said axial bore and parallel with the first and second bosses;
• obtaining a bearing assembly from a source and inserting the bearing assembly into the axial bore of the knuckle;
• obtaining a wheel hub from a source, said wheel hub being defined by a second cylindrical body with a first end and a second end, a pilot surface that extends from the first end to a peripheral radial mounting flange that is located between the first end and the second end, said mounting flange having a plurality of axial openings that are located a fixed radial distance from an axis of said second cylindrical body, and a peripheral bearing surface that extends from the second end to a shoulder adjacent the radial mounting flange;
• attaching said wheel hub to said knuckle with the bearing assembly being located on said peripheral bearing surface;
• placing said knuckle in a second fixture and holding said knuckle in the second fixture by clamping on said plurality of locator pads;
• thereafter, rotating said wheel hub while machining said mounting flange to remove any material thereon not in parallel alignment with the bases of said plurality of locator pads;
• and
• finally machining said first and second bosses to assure that the first and second bosses are in parallel alignment with the plurality of locator pads.