Method of manufacturing a monotube shock absorber

1. A method of manufacturing a shock absorber, the method comprising:

inserting a floating piston into a tube;

disposing oil into the tube;

inserting a piston-rod assembly having a piston coupled to a rod into the tube;

inserting a rod guide assembly into the tube, wherein the rod guide assembly comprises a sintered metal rod guide having a seat and a seal disposed in the seat, wherein the rod extends through the seal;

staking the sintered metal rod guide, wherein the staking deforms a top end of the sintered metal rod guide to form a plurality of stake holds that engage the seal to secure the seal to the sintered metal rod guide;

deforming a wall of the tube into engagement with the sintered metal rod guide to provide a piston-cylinder assembly and inhibit axial movement of the rod guide assembly relative to the tube;

pressurizing the piston-cylinder assembly; and

forming a flange portion of the tube over an upper surface of the sintered metal rod guide such that the flange portion is in sealing contact with the seal.

2. The method according to claim 1 , wherein the step of staking the sintered metal rod guide is performed before inserting the rod guide assembly into the tube.

3. The method according to claim 1 , wherein the tube comprises a bottom end portion having an opening and the step of pressurizing the piston-cylinder assembly comprises applying pressure through the opening in the bottom end portion of the tube.

4. The method according to claim 3 further comprising closing the opening in the bottom end of the tube to form a pressurized gas reservoir defined by the floating piston and the tube.

5. The method according to claim 1 , wherein the step of staking the sintered metal rod guide is performed after deforming the wall of the tube into engagement with the sintered metal rod guide, wherein deforming the wall of the tube into engagement with the sintered metal rod guide includes deforming the wall of the tube into a recess defined by the sintered metal rod guide.

6. The method according to claim 1 , wherein the step of forming the flange portion of the tube over an upper surface of the sintered metal rod guide is performed after pressurizing the piston-cylinder assembly.

7. The method according to claim 1 further comprising sintering metal to form the sintered metal rod guide, wherein the sintered metal rod guide has a first region that has a first density and a second region that has a second density that is less than the first density, wherein the seat is in the first region and the staking is performed on the second region.

8. The method according to claim 1 , wherein the tube comprises a closed bottom end portion and the method further comprises moving the floating piston within the tube toward the bottom end portion of the tube to form a pressurized gas reservoir below the floating piston.

9. The method according to claim 1 , wherein the step of forming the flange portion of the tube over the upper surface of the sintered metal rod guide includes rolling the flange portion over the upper surface of the sintered metal rod guide so that the flange portion contacts the seal.

10. The method according to claim 1 , wherein the tube and the floating piston define a gas reservoir, wherein pressurizing the piston-cylinder assembly includes:

raising a pressure within the gas reservoir to a test pressure; and

monitoring the shock absorber for leaks while at the test pressure,

wherein raising the pressure within the gas reservoir to the test pressure and monitoring the shock absorber for leaks while at the test pressure are performed before forming the flange portion of the tube over the upper surface of the sintered metal rod guide.

11. The method according to claim 1 , further comprising testing a damping of the shock absorber before forming the flange portion.

12. The method according to claim 1 , wherein the seal includes a washer and a resilient seal body that forms a seal between the flange portion and the washer after forming the flange portion of the tube over the upper surface of the sintered metal rod guide, wherein the stake holds extend radially inward of an outer perimeter of the washer to inhibit axial movement of the seal.

13. A method for assembling a shock absorber, the method comprising:

inserting a floating piston into a tube;

disposing oil into the tube on top of the floating piston;

inserting a piston-rod assembly having a piston and a rod into the tube to form an oil reservoir between the floating piston and the piston of the piston-rod assembly;

inserting a rod guide assembly into the tube, the rod guide assembly comprising a sintered metal rod guide and a seal, wherein the rod extends through the seal and is in sealing contact with the seal, wherein the sintered metal rod guide includes a seat surface and a groove, the seat surface being recessed from a top end of the sintered metal rod guide, the groove being recessed in the seat surface, wherein the seal includes a resilient body that defines a static seal portion and a dynamic seal portion, wherein the seal contacts the seat surface and a lower lip of the static seal portion is received in the groove to form a seal therein with the sintered metal rod guide, wherein the dynamic seal portion contacts the rod;

crimping a wall of the tube into engagement with the sintered metal rod guide to form a piston-cylinder assembly to inhibit axial movement of the sintered metal rod guide relative to the tube;

pressurizing the piston-cylinder assembly; and

rolling a flange portion of the tube over an upper surface of the sintered metal rod guide such that the flange portion is in sealing contact with the seal, wherein rolling the flange portion of the tube occurs after pressurizing the piston-cylinder assembly.

14. The method according to claim 13 , wherein the step of pressurizing the piston-cylinder assembly comprises applying pressure through a bottom end portion of the tube.

15. The method according to claim 13 further comprising staking the sintered metal rod guide to secure the seal to the sintered metal rod guide.

16. The method according to claim 15 , wherein the step of staking the sintered metal rod guide is performed before pressurizing the piston-cylinder assembly.

17. The method according to claim 13 , wherein the static seal portion includes an upper lip in sealing contact with the flange portion after rolling the flange portion of the tube over the upper surface of the sintered metal rod guide.

18. A method of manufacturing a shock absorber, the method comprising:

inserting a floating piston into a tube;

disposing oil into the tube;

inserting a piston-rod assembly having a piston coupled to a rod into the tube;

inserting a rod guide assembly into the tube, wherein the rod guide assembly comprises a sintered metal rod guide having a seat and a seal disposed in the seat, the sintered metal rod guide having a first region that has a first density and a second region that has a second density that is less than the first density, wherein the seat is in the first region and the rod extends through the seal;

deforming a wall of the tube into engagement with the sintered metal rod guide to provide a piston-cylinder assembly and inhibit axial movement of the rod guide assembly relative to the tube;

staking the sintered metal rod guide to secure the seal to the sintered metal rod guide, wherein the staking is performed on the second region;

pressurizing the piston-cylinder assembly; and

forming a flange portion of the tube over an upper surface of the sintered metal rod guide.

19. The method according to claim 18 , wherein the step of pressurizing the piston-cylinder assembly comprises applying pressure through a top end of the tube.

20. The method according to claim 18 , wherein the sintered metal rod guide comprises a groove and the seal comprises a static seal portion and a dynamic seal portion, the static seal portion including a lower lip disposed in the groove and an upper portion in contact with the flange.