Shaft seal assembly

1. A seal assembly for sealing a steering knuckle to an axle shaft and to a wheel hub of a vehicle, comprising:

an inner case and an outer case disposed radially outwardly of said inner case;

said outer case extending from a first end to a second end;

a one piece elastomeric member secured with said outer case and including at least one lip in sliding contact with said inner case to establish a liquid-tight seal between said inner and outer cases when said inner case is rotated relative to said outer case;

said elastomeric member having an outer surface which extends between opposite axial ends and is disposed on an outer radial side of said outer case;

said outer surface of said elastomeric member including at least one locking feature for locking said seal assembly with one portion of the steering knuckle and including a generally flat portion and including a castellated feature that is disposed adjacent one of said axial ends on an opposite axial side of said generally flat portion from said locking feature;

said castellated feature extending in an axial direction past one of said first and second ends of said outer case and in a radial direction past said generally flat portion; and

said castellated feature including a plurality of generally L-shaped grooves with radially extending legs and axially extending legs, said L-shaped grooves being spaced circumferentially from one another, said radially extending legs extending in a radial direction past said one of said first and second ends of said outer case, and said axially extending legs extending axially to said generally flat portion of said elastomeric member.

2. The seal assembly as set forth in claim 1 wherein said elastomeric member secured with said outer case is a first elastomeric member.

3. The seal assembly as set forth in claim 2 wherein said first elastomeric member is in overmolded engagement with said outer case.

4. The seal assembly as set forth in claim 2 further including a second elastomeric member in engagement with said inner case.

5. The seal assembly as set forth in claim 4 wherein said second elastomeric member is in overmolded engagement with said inner case.

6. The seal assembly as set forth in claim 4 wherein said outer case includes an outer rim and wherein at least a portion of said first elastomeric member extends circumferentially around and said outer rim of said outer case for engaging an inner bore of the steering knuckle of the vehicle.

7. The seal assembly as set forth in claim 6 wherein said first elastomeric member includes a plurality of locking ribs.

8. The seal assembly as set forth in claim 6 wherein said inner case includes an axially extending portion and wherein at least a portion of said second elastomeric member extends along the inner circumference of said axially extending portion of said inner case for engaging the axle shaft of the vehicle.

9. The seal assembly as set forth in claim 8 wherein said second elastomeric member includes a plurality of locking ribs.

10. The seal assembly as set forth in claim 4 wherein said first elastomeric member includes at least one sealing lip extending radially to slidably abut said inner case.

11. The seal assembly as set forth in claim 10 further including a garter spring extending circumferentially around a portion of said first elastomeric member to bias said at least one sealing lip against said inner case.

12. The seal assembly as set forth in claim 4 wherein said outer case includes a first leg extending in a radially inward direction, wherein said inner case includes a second leg extending in a radially outward direction, and wherein said first and second legs are spaced axially from one another.

13. The seal assembly as set forth in claim 12 wherein at least one of said first and second elastomeric members includes at least one sealing lip extending axially between said first and second legs to restrict the passage of contaminants across said seal assembly.

14. The seal assembly as set forth in claim 13 wherein said first and second elastomeric members are shaped to present a labyrinth therebetween.

15. A front wheel assembly for a vehicle, comprising:

a steering knuckle having a vacuum port;

an axle shaft;

a pressure-activated locking hub for selectively engaging with and disengaging from said axle shaft; and

a seal assembly including;

an inner case and an outer case disposed radially outwardly of said inner case,

a one piece elastomeric member secured with said outer case and including at least one lip in sliding contact with said inner case to establish a liquid-tight seal between said inner and outer cases when said inner case is rotated,

said elastomeric member having an outer surface which extends between opposite axial ends and is disposed on an outer radial side of said outer case and is sealed directly against said steering knuckle and has a generally flat portion and a castellated feature,

said castellated feature being disposed adjacent one of said axial ends of said elastomeric member, and

wherein said castellated feature includes a plurality of projections that extend axially and radially and are spaced circumferentially from one another by L-shaped grooves with radially extending legs and axially extending legs to present an air path which extends from said pressure activated locking hub through said axially extending legs and said radially extending legs of said L-shaped grooves and into a gap between said outer surface of said elastomeric member and said steering knuckle and into said vacuum port of said steering knuckle.