1. Chassis Technology for Commercial Vehicles
Safety and Comfort

2. 2
Contents
Chassis technology Page 4
Suspension system Page 6
Independent suspension Page 8
Steering system Page 12
Cabin suspension Page 14
Research and Development Page 16
Production plants worldwide Page 20
The ZF Group Page 22

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Reliable in Quality and Technology
For more than 60 years, ZF has been
­supplying innovative chassis products
to manufacturers of trucks, buses,
­agricultural machinery, construction
­machinery, special vehicles, and rail
­vehicles. Within the ZF Group,
we are the ­specialists for CV chassis
­modules. As a partner for added value
in the commercial vehicle industry,
we work with state-of-the-art technology
and – as a global leader – offer our
­customers the best solutions in the
product lines axle and wheel suspension,
steering components and driver´s cabin
suspension.

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materials such as aluminum v-links or design improve-
ments using die-casting technology for torque rods and
v-links. Another way of reducing weight is function in-
tegration, achieved for instance with our 4-point links.
These optimizations are aimed at reducing costs and
improving driving dynamics. The focus here is on the
chassis as a safety component.
Study: 4-point link made of fibre-plastic composite
material
ZF is working on manufacturing 4-point links from
fibre-plastic composites instead of die-cast material.
This drives forward developments both in functional
lightweight construction and in the use of lightweight
materials. In a corresponding concept study, we were
able to construct a 4-point link using GRP, making a
part that is some 25 percent lighter than the die-cast
version.
This is how we develop optimum chassis technology
with outstanding safety standards – the basis for
problem-free transport of goods weighing several
tons. Short development times from initial talks to
components ready for production and strict compliance
with technical specifications guarantee top customer
satis­faction. That‘s a promise.
Lightweight chassis design
We are committed to the permanent improvement
of our products and processes. ZF optimizes lightweight
construction with new materials and engineering
­processes, with innovative product design and exten-
sive process experience. The business unit provides
essential impetus for continuous weight reduction in
commercial vehicle construction. Our product inno­
vations increase the payload, reduce fuel consumption,
and enhance the comfort of commercial vehicles.
The result of this optimization is the use of lightweight
Our design expertise guarantees fast implementation of growing
safety requirements and increasing comfort standards.
Expertise in Chassis
Technology
4

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4-point links in die-cast version
Other PRODUCTS
V-links made of aluminum
Chassis stabilizer
V-links with transverse lug
Torque rod adjustable on both sides
Torque rod in die-cast version
4-point links
Study using glass fiber-reinforced
plastic composite

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hollow-cast design. The live rear axle features a
­stabilizer link with new polygon joining technology:
­Together with a lightweight aluminum v-link and
a spring bellows carrier, it takes over both the axle
­guidance in longitudinal and transversal direction
and the vertical axle load support. Thanks to the
design enhancements on both axles, the new rear-axle
­suspension weighs far less, leading to less unsprung
masses in the vehicle. This is of great importance
for safety and comfort. Fleet owners benefit from a
lower vehicle weight because then the payload can be
­increased and the relative fuel consumption reduced.
­Another positive side effect of the weight reduction
is the reduced ­damage to the road surface, and lower
wear of the chassis bearings.
Here, shedding a few pounds not only helps to reduce
fuel consumption but also increases the loading
­capacity. Reduced unsprung masses in the chassis
also ­translate into greater comfort and reduced wear
on bearings.
This is where ZF supplies the innovative rear axle
suspension system as a complete solution. Function
integration and lighter materials slash weights, both
of 4-point links and of the overall system.
Innovative twin rear axle suspension
The cast version of the 4-point link is part of a weight-
optimized truck suspension system for the rear twin
axle. Here, the 4-point link is responsible for locating
the non-driven leading axle with its weight-optimized
What is already commonplace in other industries, such as aviation,
has only recently been increasingly adopted in the commercial vehicle
sector: lightweight construction to increase efficiency. In addition to
the driveline, ZF has primarily been slimming down the truck chassis.
Systemized Performance
The suspension system
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Rear axle suspension
Other PRODUCTS
Rear axle suspension
with 4-point link
Rear axle suspension
with stabilizer link
and aluminum v-link
Rear axle suspension
for twin axles with 4-point link
as well as v-link and stabilizer link
Rear axle suspension
with stabilizer link
Rear axle steel suspension

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We cooperate intensively with our customers – from
development to volume production. We take on the
­development work right through to the design of
­efficient logistics concepts to give our customers the
space to focus on their business.
Zero maintenance, low noise
ZF links are maintenance-free and low-noise.
They come with the options of molecular or plain
­bearings and are made with precisely defined rigidity.
That not only dampens vibrations, but also systema­
tically ­produces elastokinematic properties.
That is why ZF started developing independent suspen-
sion systems according to the principle of double-wish-
bone axles at an early stage. This successful concept
is set to be applied increasingly in trucks as well as
special vehicles because the benefits in terms of safety
and comfort apply here as well. Within the ZF Group,
we are able to develop and supply complete systems
– including suspension systems, spring ­suspensions,
damping, and brakes – for front and rear axles.
ZF – your development partner.
Cooperation within the ZF Group is a given, but ZF is
also a development partner for many systems suppliers
worldwide. We develop and supply ready-to-install
­modules for the axle systems of our customers.
Independent suspension components. More safety and comfort
in commercial vehicles. The demand for even better passenger
comfort in buses requires new axle suspension concepts.
Competence in Innovation
and Comfort
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Control arms for independent suspensions
Other PRODUCTS
Control arms in die-cast design
Control arms for driven axles
in special vehicles
Suspension joint
for control arms
Control arms for driven axles
in special vehicles
Control arms in die-cast design
Corner module
for special vehicles

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Comfort, efficiency, reliability -
based on these standards, ZF deve-
loped its new IS 80 TF independent
suspension for heavy trucks. It
weighs 40 kg less compared to the
current air spring rigid axle which
is guided by control arms. This is
also a weight advantage of more
than ten percent compared to the
current independent suspension.
This was achieved by further deve-
loping the steering knuckle support
principle. The control arms have
been extended towards the king pin
and have been directly connected
to it. The spring forces are now
­supported by a separate, compact
spring carrier. For this reason, the
steering knuckle support could be
omitted completely. This reduces
the unsprung masses, enhances the
axle kinematics, and allows for
larger suspension travel. Like this,
road bumps can be more easily
compensated by the chassis, which
reduces the stress for vehicle and
driver. Especially in long-distance
traffic with heavy trucks, high
comfort is a central criterion for a
workplace that reduces tiring and
protects the driver’s back. The axle
halves of the independent suspen-
sion are designed as pre-assembled
units. The kinematics and installa-
tion space consider the ladder-type
chassis typical for trucks as well as
the space requirements of the drive-
line. Furthermore, large steering
angles guarantee an ideal turning
radius. The development target,
however, was not only to improve
the driving comfort, but also to
The new independent front suspension for heavy-duty trucks
significantly increases comfort and improves handling.
Smaller unsprung masses and ideal damping reduce fuel
consumption and wear.
Innovation leap:
ZF independent truck suspension

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protect the road surface. Apart from
the smaller unsprung masses, the
Air Spring Damper Module (LDM)
by ZF contributes to this target as it
enables an ideal damping and chas-
sis suspension with the lowest
possible demand for installation
space. Like this, transport goods
arrive at the end customers without
any damage even in case of poor
road conditions. Thus, the IS 80 TF
independent suspension sets new
standards for a more economic way
of transporting goods. The lower
total weight saves fuel and keeps
the emission values on a low level.
The design considers the truck’s
available installation space and
offers the vehicle manufacturer
good conditions for integrating
modern chassis technology.

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commercial vehicles has achieved high market success.
The successful product sets new standards with its low
weight and space-saving dimensions, and impresses
with improved wheel guidance behavior and reduced
noise. Meanwhile, well over 15 million joints have
­already left the shop floor at the ZF Dielingen location.
Custom solutions
Whatever your requirements, we find the best solu-
tions. Take for instance our lubricated joint developed
­especially for the North American market. It builds on
the maintenance-free design of joint components that
has proved its value millions of times over. This design-
to-market solution means customers can choose either
the maintenance-free or the lubricated version.
For example excellent quality and cost-effectiveness,
reduced weight, integration of functions, and the latest
technology. This is what the global market expects from
us. ZF has the right responses to these requirements.
We find the ideal solution even for the most challenging
installation spaces. Using state-of-the-art development
and manufacturing tools, we meet our customers‘
­demands.
Innovative products from ZF
When it comes to our proven ZF joint design or our
fine-tuning system for tie rods and drag links, we set
the benchmark. We stand for zero maintenance, low
weight, and space-saving design. Also high on our list
of priorities are reliability and long service life.
Since the start of high-volume production in 2000,
the new ZF joint design for tie rods and drag links in
Steering systems. Our philosophy: simply the best solutions for you.
Customized solutions and ready-to-install products for commercial
vehicles have to meet high requirements.
Benchmarks in Design and
Service Life
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Steering rod for connection of steering axles
Other PRODUCTS
Tie rod with offset housing
Offset housing
Tie rod with bend
Tie rod
with inner ball joint
Tie rod with fine-tuning system
Fine-tuning system

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appli­cations. The requirements range from robust
off-road capabilities, e.g. for construction vehicles or
tractors, to comfort-optimized designs for long-distance
driving on freeways.
Expansion of our cabin suspension product line
In 2012, we significantly expanded our cabin suspen­
sion product line. Now, even more joining technologies
have been added to our proven polygon pressed joint
method for driver‘s cabin anti-roll bars. This means we
can offer our customers new product versions. Apart
from conventional welding, we also use the innova-
tive Magnetarc welding process. It enables us to weld
­different metallic materials together. That results in
high-strength, high-tightness adhesive connections.
As a systems supplier, ZF develops and produces cabin
suspensions for all applications in commercial vehicles
– including springs, vibration dampers, and rubber-­
metal components. Every time, we offer you the opti-
mal solution customized to your requirements.
Drivers benefit from a more comfortable workplace
with fewer jolts, pitching, or rolling motions. The
various ­commercial vehicle fields of operation require
different cabin types that in some cases differ widely
in terms of dimensions, features, and weight.
Comfort and optimized use of space
ZF develops cabin suspensions for various require-
ments. The result? Good working conditions for
drivers.Just like the commercial vehicles themselves,
the cabin suspensions are designed for very different
ZF cabin suspensions ensure driver comfort and optimize both functions
and space. Good working conditions in commercial vehicles are not a
luxury but a prerequisite for getting the driver, vehicle, and goods safely
to their destination.
Comfort for the Driver‘s Cab
Innovative cabin suspension
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Other PRODUCTS
Driver‘s cabin anti-roll bar
with welded joint
Driver‘s cabin anti-roll bar
with polygon pressed joint
Driver‘s cabin suspension system with
rear active roll stabilization system
Driver‘s cabin anti-roll bar
with Magnetarc welded joint
Driver‘s cabin suspension system with passive roll stabilization
Driver‘s cabin suspension system with
front active roll stabilization system

16. Innovations – not an end in themselves! They must pay off:
for manufacturers, fleet owners, and drivers, but also for the environment
and society. In view of these conflicting criteria, each new development
must prove worthwhile.
Research and Development
to Secure Mobility
16
3D-CAD, FEM (linear and non-linear), FEM according
to the principle of organic growth (CAO), shaping
­simulation, and MBS. Our 3D-CAD system supports
short development times worldwide, plus precise
­compliance with technical specifications. The rapid
adoption of our customers‘ and suppliers‘ models is
a major step toward the best solutions.
Safety thanks to state-of-the-art technology
Safety and quality due to prototype construction and
component testing: The development of inno-vative
solutions at ever-shorter intervals is crucial for the
commercial vehicle industry. Supported by the appli-
cation-oriented prototype construction and effective
component testing at ZF, our customers are always
on the safe side.
Our experience and expertise pays off for our
­customers. The quality of our products is vital for
­people who are dependent on their functional safety.
We carefully plan quality from the outset – in the
­concept phase – and ensure it is included throughout
all phases. Audits, also according to TS 16949,
regularly confirm this.
Because we implement a comprehensive quality
­management system, you can rely not only on quality,
but also on service and cost-effectiveness.
The ZF Group benefits from an international network
of development centers: The main development loca-
tions are Friedrichshafen, Dielingen, Passau, Schwein-
furt, Schwäbisch Gmünd, Northville near Detroit
(USA), Pilsen (Czech Republic), and Shanghai (China).
Worldwide, approximately 5,400 engineers work in
Research and Development. Corporate R&D coordinates
and supports the activities at the development center
in Tokyo (Japan). Every year, ZF invests approximately
five percent of its sales in Research and Development.
With success, because innovative products from ZF set
the standards for state-of-the-art technology – again and
again.
Development work at ZF is organized according to
decentralized and central functions. The divisions and
business units focus on markets and product expertise,
ensuring customer-centered, competitive technolo­
gical product development. Corporate R&D works
with a strong emphasis on basic research and theory
and ­supports the functional development areas in the
divisions.
The fast and precise way to optimal solutions
The CV Chassis Modules Business Unit develops com-
plex products in Dielingen with cutting-edge technology
and according to the latest methods. Included here are

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development Center
Measuring wheel Measured data recording under realistic
conditions
Development department
Development location Dielingen Concept and design development CAD representation Multi-body simulation
(MBS)
Multiaxial test bench for CV axle systems
On the test bench, commercial vehicle chassis modules are tested under simulated conditions analogous to
those during daily truck operation on the road. The test bench can apply loads of up to 36 tons onto the axle.
With the test bench, ZF is able to develop and test entire axle suspension systems.

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joining components reduce wear on materials and save
weight. They ensure safe comfort at high speeds. That
guarantees perfect, reliable, and sustainable products.
ZF is committed to the mobility of people and goods.
Innovations that move you – chassis modules from ZF.
Today‘s chassis systems must perform ever better. Not
only in commercial vehicles or buses. Higher top speeds
combined with off-road capabilities, these are proper-
ties required of independent suspension solutions for
construction and agricultural vehicles.
The rail industry also benefits from our solutions. Our
vibration-absorbing torque supports as well as flexible
From vans to 9-axle heavy-load cranes, from tractors
to high-speed trains. We supply our products for various
applications to a whole range of industries.
CV chassis modules in various
types of commercial vehicles
and industries
18
Innovation support truck chassis

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Production Plants for
CV chassis modules:
Your Partner Worldwide
20
Global synergies create clear benefits. Wherever our
customers require our services, ZF is there for them.
Furthermore, as part of the ZF Group, we offer our
customers the synergies of a globally leading supplier
of Driveline and Chassis Technology for the automotive
industry. We are at home with all the instruments of
global sourcing. Effective project management with the
support of efficient suppliers guarantees competitive
prices and quality. By producing chassis modules in
Gainesville, Georgia (USA), Sorocaba (Brazil), Ermua
(Spain), Izmir (Turkey), Shanghai (China), and in future
also in Pune (India), we offer our customers global
­presence. They also benefit from the worldwide
locations of the entire ZF Group.
Because we are present on local markets, we respond to
the product requirements of local customers, designing
for the market. Thanks to far-reaching synergy effects,
we are the leader in many technologies connected with
commercial vehicle chassis and steering systems.
Our development potential, production know-how, and
logistical competence are at the service of commercial
vehicle manufacturers the world over.

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Sorocaba – Brazil Pune – India
Gainesville – USA
Shanghai – China
Dielingen – Germany
Ermua – Spain Izmir – Turkey
worldwide Locations

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Our enthusiasm for innovative products and processes and our uncompromising pursuit of quality have made us
a global leader in driveline and chassis technology. We are contributing towards a sustainable future by producing
advanced technology solutions with the goal of improving mobility, increasing the efficiency of our products and
systems, and conserving resources.
Our customers in the automotive and industrial sectors welcome our systematic orientation towards products and
services which provide great customer value. Improvements in energy efficiency, cost-effectiveness, dynamics,
safety, and comfort are key to our work. Simultaneously, we are aiming for continuous improvement in our busi-
ness processes and the services we provide. As a globally active company, we react quickly and flexibly to chang-
ing regional market demands with the goal of always providing a competitive price/performance ratio.
Our independence and financial security form the basis of our long-term business success. Our profitability ena-
bles us to make the necessary investments in new products, technologies, and markets and we thus secure the
future of our company on behalf of our customers, market affiliates, employees, and ZF owners.
Our tradition and values strengthen our managerial decisions. Together, they are both an obligation and an incen-
tive to maintain a reliable and respectful relationship with customers, market affiliates, and employees. Our world-
wide compliance organization ensures that locally applicable laws and regulations are adhered to. We accept our
responsibility towards society and will protect the environment at all of our locations.
Our employees worldwide recognize us as a fair employer, focusing on the future and offering attractive career
prospects. We value the varied cultural backgrounds of our employees, their competencies, and their diligence and
motivation. Their goal-oriented dedication to ZF, beyond the borders of their own field of work and location,
shapes our company culture and is the key to our success.
Shaping the future responsibly
The ZF Group

23. EN0000.762.181Edition2014
ZF Friedrichshafen AG
CV Chassis Modules
Dr.-Jürgen-Ulderup-Straße 7
32351 Stemwede
Germany
Phone +49 5474 60-0
Fax +49 5474 60-902000
www.zf.com