Salisbury axle assembly

1. A method of forming a Salisbury axle, the method comprising:

forming a Salisbury carrier assembly having a Salisbury carrier housing that is made of nodular iron, the Salisbury carrier housing having a differential opening, a first axle tube aperture and a second axle tube aperture;

installing a differential to a set of bearing journals formed by the Salisbury carrier assembly such that the differential is supported for rotation within the Salisbury carrier assembly about an axis that extends through the first and second axle tube apertures, the differential being received through the differential opening in the Salisbury carrier housing;

forming a pair of axle tubes from a steel, each of the axle tubes having a circular proximal end, a circular distal end and a mount portion between the proximal and distal ends, the proximal ends of the axle tubes being larger in diameter than the first and second axle tube apertures, the mount portion having a top wall and a pair of opposite side walls, the side walls being oriented generally perpendicular to the top wall; and

inserting the proximal ends of the axle tubes into the first and second axle tube apertures;

wherein each of the axle tubes includes a first shell member and a second shell member and wherein the method further comprises welding the first and second shell members together to form a tubular workpiece;

wherein a plane is defined where the first and second shell members abut one another and wherein the plane is disposed along a neutral axis of the Salisbury axle when the axle tubes are inserted into the first and second axle tube apertures; and

wherein the tubular workpiece has an outer surface with a first cross-sectional shape, at least a portion of the outer surface of the tubular workpiece being deformed to have a second cross-sectional shape that is different than the first cross-sectional shape.

2. The method of claim 1 , wherein prior to inserting the proximal ends of the axle tubes into the first and second axle tube apertures, the method comprises radially aligning the axle tubes to the Salisbury carrier housing.

3. The method of claim 1 , further comprising machining at least one of the proximal and distal ends of the axle tube in a metal removing operation.

4. The method of claim 1 , wherein the first cross-sectional shape is a square and the second cross-sectional shape is a circle.

5. The method of claim 1 , further comprising:

inserting a mandrel into the tubular workpiece; and

deforming the at least the portion of the outer surface of the tubular workpiece to conform to the second cross-sectional shape.

6. The method of claim 1 , wherein the first and second axle tube apertures are formed through a collar portion, wherein at least one hole is formed through each collar portion, and wherein the method further comprises welding the axle tubes through the at least one hole in the collars to inhibit relative rotation between the axle tubes and the Salisbury carrier housing.

7. A method of forming a Salisbury axle, the method comprising:

forming a Salisbury carrier assembly having a Salisbury carrier housing that is made of nodular iron, the Salisbury carrier housing having a differential opening, and a pair of collars, each of the collars defining an axle tube aperture and a hole that extends through the collar and intersects the axle tube aperture;

removing a pair of bearing caps from the Salisbury carrier housing to expose a pair of bearing journals;

installing a differential to the bearing journals, the differential being received through the differential opening in the Salisbury carrier housing;

replacing the pair of bearing caps to the bearing journals to permit the differential to be supported for rotation by the Salisbury carrier housing about an axis that extends through the axle tube apertures;

forming a pair of axle tubes from steel, each of the axle tubes having a circular proximal end, a circular distal end and a mount portion between the proximal and distal ends, the proximal ends of the axle tubes being larger in diameter than the axle tube apertures, the mount portion having a top wall that is substantially flat;

inserting the proximal ends of the axle tubes into the axle tube apertures; and

welding the axle tubes through the holes in the collars to inhibit rotation of the axle tube relative to the Salisbury carrier housing;

wherein each axle tube includes a first shell member and a second shell member that are welded to one another to form a tubular workpiece;

wherein a plane is defined where the first and second shell members abut one another and wherein the plane is disposed along a neutral axis of the Salisbury axle when the axle tubes are inserted into the first and second axle tube apertures; and

wherein the tubular workpiece has an outer surface with a first cross-sectional shape, at least a portion of the outer surface of the tubular workpiece being deformed to have a second cross-sectional shape that is different than the first cross-sectional shape.

8. The method of claim 7 , wherein the Salisbury carrier housing defines a pinion aperture, wherein the differential includes a ring gear and wherein the method further includes installing an input pinion through the pinion aperture, the input pinion meshingly engaging the ring gear.

9. The method of claim 8 , wherein a bearing supports an end of the input pinion at a location between a set of teeth on the ring gear and the axis, the bearing having an outer race that is directly coupled to the Salisbury carrier housing.

10. The method of claim 7 , wherein prior to inserting the proximal ends of the axle tubes into the axle tube apertures the method further comprises clocking the axle tube relative to the Salisbury carrier housing to orient the top surface in a predetermined orientation.

11. The method of claim 10 , wherein the top surface is generally parallel to the neutral axis of the Salisbury axle.

12. The method of claim 7 , further comprising rotatably mounting a wheel hub on each of the distal ends of the axle tubes.

13. The method of claim 7 , further comprising mounting a spring pad to each of the mount portions.