Sr. Chassis Driveline Engineer

About the Role

The Sr. Chassis Driveline Engineer will lead design, development, and validation efforts for chassis driveline systems in U.S. SUV, pickup truck, and off-road vehicles. This role involves creating robust, high-performance driveline architecture and collaborating with cross-functional teams to ensure seamless integration, meet customer requirements, and achieve durability and reliability goals.

Responsibilities

• Lead the engineering of driveline systems and components for 4WD and AWD vehicles, including transfer cases, power transfer units, and related mechanisms, to achieve performance and reliability targets.
• Design and develop axle assemblies and shaft components (e.g., solid rear axles, front/rear half-shafts, prop shafts, and driveshafts) to withstand high-torque loads and off-road conditions while meeting weight and durability goals.
• Engineer advanced differential systems (e.g., limited-slip units, torque-vectoring differentials, and electronic-locking differentials) to optimize traction, handling, and stability for both on-road and extreme off-road usage.
• Define, support, and execute comprehensive DVP&R (Design Verification Plan & Report) test plans for driveline components, including bench tests, dynamometer tests, and vehicle field tests (on-road and off-road) to validate performance, durability, and NVH characteristics.
• Analyze test data and drive iterative design improvements based on results.
• Monitor and troubleshoot driveline-related issues throughout the development cycle, supporting root cause analysis (e.g., 5-Whys, Fishbone) and implementing design or process changes to resolve issues.
• Work closely with cross-functional teams—including Vehicle Dynamics, Suspension, Powertrain, NVH, Manufacturing, and Quality—to ensure seamless integration of driveline systems into Hyundai, Kia, and Genesis vehicles.
• Coordinate packaging studies, interfaces, and systems integration to avoid conflicts and achieve performance objectives.
• Liaise with OEM and Tier 1 suppliers for driveline components, reviewing and validating supplier designs or changes to ensure they meet specifications and quality standards.
• Oversee supplier development activities and support sourcing and manufacturing processes for driveline parts.
• Ensure all designs comply with regulatory and industry standards, such as Federal Motor Vehicle Safety Standards (FMVSS) and SAE standards for chassis and driveline systems.
• Create and maintain detailed engineering documentation, including 3D models and 2D drawings in CATIA V5 (with GD&T as needed), technical specifications, DFMEAs, design review materials, and engineering reports.
• Mentor junior engineers on best practices and facilitate on-the-job learning.
• Stay current with emerging technologies and trends in driveline and off-road vehicle systems, proposing innovative solutions (e.g., novel torque management systems or lightweight materials) to enhance performance and reliability.
• Lead or contribute to advanced engineering projects aimed at improving driveline efficiency, durability, and functionality.
• Travel up to 20% of the time, both domestically and internationally.

Requirements

• Bachelor’s degree in mechanical engineering, automotive engineering, or a related field.
• 7+ years of professional experience in chassis and suspension design, with a focus on driveline systems.
• Experience with pickup trucks, SUVs, or off-road vehicles is highly preferred.
• In-depth understanding of vehicle ride and handling, off-road performance, and NVH considerations specific to heavy-duty trucks and SUVs.
• Proficiency in CATIA V5, with the ability to create complex part models, assemblies, and engineering drawings with proper GD&T annotation.
• Familiarity with PDM (e.g., ENOVIA V6) or Windchill PLM systems.
• Knowledge of mechanical, industrial, or manufacturing engineering design and processes, including tooling design variables and materials.
• Strong problem-solving skills, with the ability to diagnose complex issues (e.g., failure analysis) and develop robust solutions under tight timelines.
• Excellent written, oral, interpersonal, and leadership skills.
• Valid Driver’s License and a satisfactory driving record.

Preferred Qualifications

• Master’s degree in mechanical engineering, automotive engineering, or a related field.
• Proficiency in CAE tools (e.g., ANSYS, Nastran, MATLAB/Simulink) for advanced suspension modeling, dynamic simulations, and product optimization.
• Professional Engineer (PE) license or Six Sigma certification.
• Experience with vehicle program launches (from concept to production).
• Project management experience.

Benefits

• Zero-dollar employee premiums on medical, dental, and vision coverage for you and your family.
• 100% employer-paid disability and life insurance.
• Generous paid time off, including vacation, sick leave, and holidays.
• Competitive salaries.
• Retirement savings and planning benefits.
• Access to health savings accounts and flexible spending accounts.
• Flexible work hours.
• Global environment fostering diversity.