Devices and systems for preventing misalignment in vehicle brake assemblies

Abstract

A vehicle brake assembly includes an actuation lever coupled to a brake pedal. The brake assembly also includes a push rod of a brake booster. The push rod has a clevis on an end portion thereof. The clevis comprises two prongs. The brake assembly further includes an alignment device seated on each respective prong of the clevis. The alignment devices are configured to collectively guide and position the clevis into alignment with the actuation lever during construction of the brake assembly.

What is claimed is: 
     
         1 . A vehicle brake assembly, comprising:
 an actuation lever coupled to a brake pedal;   a push rod of a brake booster, the push rod having a clevis on an end portion thereof, the clevis comprising two prongs; and   an alignment device seated on each respective prong of the clevis,   wherein the alignment devices are configured to collectively guide and position the clevis into alignment with the actuation lever during construction of the brake assembly.   
     
     
         2 . The assembly of  claim 1 , wherein the actuation lever is a brake pedal arm. 
     
     
         3 . The assembly of  claim 1 , wherein the actuation lever is coupled to a brake pedal arm. 
     
     
         4 . The of  claim 1 , wherein each alignment device comprises a body that is configured to slide over a respective prong of the clevis and a sliding surface that extends laterally away from the body. 
     
     
         5 . The vehicle brake assembly of  claim 4 , wherein the sliding surfaces of the alignment devices collectively form a funnel configured to guide and position the clevis into alignment with the actuation lever. 
     
     
         6 . The vehicle brake assembly of  claim 1 , wherein each alignment device comprises a spacer lug that is configured to extend laterally outward for a predefined distance from a respective prong of the clevis. 
     
     
         7 . The vehicle brake assembly of  claim 6 , wherein the spacer lugs are integrally formed with the prongs of the clevis. 
     
     
         8 . A method of constructing a vehicle brake assembly comprising an actuation lever and a brake booster, comprising:
 attaching an alignment device to each respective prong of a pair of prongs forming a clevis at an end of a push rod of the brake booster;   guiding the clevis into alignment with the actuation lever via the alignment devices; and   coupling the clevis to the actuation lever.   
     
     
         9 . The method of  claim 8 , wherein attaching an alignment device to each respective prong comprises sliding an alignment device on each respective prong, wherein a body of the alignment device is shaped to sit on the prong. 
     
     
         10 . The method of  claim 9 , wherein attaching a respective alignment device to each prong comprises affixing a respective spacer lug to each prong, wherein the spacer lug extends laterally outward for a predefined distance from the prong. 
     
     
         11 . The method of  claim 9 , wherein guiding the clevis into alignment with the actuation lever comprises guiding the clevis over the actuation lever such that the actuation lever arm is positioned between the pair of prongs of the clevis and a hole in each of the pair of prongs is aligned with a respective bushing hole in the pedal arm. 
     
     
         12 . The method of  claim 12 , wherein coupling the clevis to the actuation lever comprises inserting a pin through the aligned holes of the clevis and the pedal arm.