Knuckle and bushing assembly

A method for manufacturing an integrated knuckle and bushing assembly comprising the steps of:

• producing a knuckle member having a passage extending there through, the knuckle member for providing support for a suspension member, the knuckle member having a first extension member located at one end of the passage of the knuckle member and further defining the passage and a second extension member located at a second end of the passage of the knuckle member and further defining the passage, wherein the first extension member and the second extension member each extend in a direction aligned with a center axis of the passage;
• producing a bushing having a passage extending there through and plurality of annular reduced portions located in an exterior surface of the bushing, wherein the bushing includes an outer member having a center portion, a first ear, and a second ear;
• locating the bushing to be axially aligned in the passage in the knuckle member so that the knuckle member contacts the first ear and the second ear while the first extension member and the second extension member each extend in a direction aligned with the center axis of the passage, the bushing for providing improved radial, torsional and conical support to the suspension member to be located within the passage in the bushing;
• and
• forming the first extension member to extend at least partially in a direction perpendicular with the center axis of the passage and over at least a portion of the first end of the bushing;
• and
• forming the second extension member to extend at least partially in a direction perpendicular with the center axis of the passage and over at least a portion of the second end of the bushing to secure the bushing within the passage of the knuckle member;
• wherein the knuckle member has an arcuate portion generally extending between the first extension member and the second extension member and generally perpendicular to the first passage.

A method for manufacturing an integrated knuckle and bushing assembly for use in a suspension assembly in a vehicle, the method comprising the steps of:

• producing a knuckle member having a passage extending there through, the knuckle member for providing support for a suspension member, the knuckle member having a first extension member located at one end of the passage of the knuckle member and further defining the passage and a second extension member located at a second end of the passage of the knuckle member and further defining the passage, wherein the first extension member extends in a direction aligned with the center axis of the passage and the second extension member is formed to close the second end of the passage when the knuckle member is produced;
• producing a bushing having a passage extending there through and a plurality of annular reduced portions located in an exterior surface of the bushing, wherein the bushing includes an outer member and an inner member, the outer member having a center portion, a first ear, and a second ear, wherein the ears are spaced apart by the center portion, and wherein the inner member includes a spherical portion;
• locating the bushing to be axially aligned in the passage in the knuckle member by press fitting the bushing in the passage through the first end, so that the knuckle member contacts the first ear and the second ear while the first extension member extends in a direction aligned with the center axis of the passage, the bushing for providing improved radial, torsional and conical support to the suspension member to be located within the passage in the bushing;
• and
• forming the first extension member to extend at least partially in a direction substantially perpendicular with the axial axis of the passage and to overlap with at least a portion of the first end of the bushing to secure the bushing within the passage of the knuckle member, wherein the step of forming the first extension member is after the step of locating the bushing.