Vehicle drum-in-hat disc brake assembly and method for producing same

1. A vehicle drum-in-hat disc brake assembly comprising:

a shield adapted to be secured to an axle flange;

a drum brake portion carried by the shield;

an abutment tower operatively disposed with the drum brake portion; and

a caliper bracket assembly formed separate from the abutment tower and adapted to be secured to the axle flange;

wherein at least one first fastener is provided for securing the abutment tower to the caliper bracket assembly and a plurality of second fasteners are provided for securing the caliper bracket assembly and the shield to the axle flange;

wherein the plurality of second fasteners include a first plurality of second fasteners which extend through openings provided in the caliper bracket, through openings provided in the axle flange, and are received in threaded openings provided in the abutment tower to secure the caliper bracket and the abutment tower to the axle flange, and a second plurality of second fasteners which extend through openings provided in the shield and are received in threaded openings provided in the axle flange to secure the shield to the axle flange.

2. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes at least one threaded hole for receiving the at least one first fastener for securing the abutment tower to the caliper bracket assembly.

3. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes a pair of arms, each arm having an extension having a reduced outer diameter and a threaded opening formed therethrough, the axle flange includes a pair of countersunk holes, and wherein the reduced outer diameter extensions are disposed in the countersunk holes.

4. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes a portion for attaching a wheel speed sensor.

5. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the caliper bracket assembly includes a slot and the abutment tower includes a key which is adapted to be guided in the slot to assist in the mating of the abutment tower to the caliper bracket assembly during assembly.

6. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the caliper bracket assembly includes a caliper bracket and a piston caliper assembly.

7. The vehicle drum-in-hat disc brake assembly of claim 6 wherein the caliper bracket is disposed on an inboard side of the axle flange.

8. A method for producing a vehicle drum-in-hat disc brake assembly comprising the steps of:

(a) providing an assembled drum brake assembly including a shield adapted to be secured to an axle flange of an axle, a drum brake portion carried by the shield, and an abutment tower operatively disposed with the drum brake portion;

(b) providing a caliper bracket assembly formed separate from the abutment tower of the assembled drum brake assembly provided in step (a);

(c) installing the assembled drum brake assembly on the axle;

(d) installing a brake rotor on the axle;

(e) installing the caliper bracket assembly on the axle;

(f) providing at least one first fastener for securing the abutment tower to the caliper bracket assembly; and

(g) providing a plurality of second fasteners for securing the caliper bracket assembly and the shield to the axle flange, wherein the plurality of second fasteners include a first plurality of second fasteners which extend through openings provided in the caliper bracket, through openings provided in the axle flange, and are received in threaded openings provided in the abutment tower to secure the caliper bracket and the abutment tower to the axle flange, and a second plurality of second fasteners which extend through openings provided in the shield and are received in threaded openings provided in the axle flange to secure the shield to the axle flange.

9. The method of claim 8 wherein the abutment tower includes at least one threaded hole for receiving the at least one first fastener for securing the abutment tower to the caliper bracket assembly.

10. The method of claim 8 wherein the abutment tower includes a pair of arms, each arm having an extension having a reduced outer diameter and a threaded opening formed therethrough, the axle flange includes a pair of countersunk holes, and wherein the reduced outer diameter extensions are disposed in the countersunk holes.

11. The method of claim 8 wherein the caliper bracket assembly includes a slot and the abutment tower includes a key which is adapted to be guided in the slot to assist in the mating of the abutment tower to the caliper bracket assembly during assembly.