Abstract: A method of manufacturing a torsion bar for a steering system is provided. The method includes supporting a torsion bar blank on a cold forming machine with a plurality of dies at a first end region of the torsion bar blank and a second end region of the torsion bar blank. The method also includes rolling the torsion bar blank to form an end region having a cylindrical outer surface extending from an axial end surface and a serrated portion disposed proximate the end region and axially offset from the axial end surface.

Abstract: A power steering system includes a rack housing arranged to receive a longitudinally displaceable rack member. The system also includes an assist cover connected to the rack housing, the rack housing and the assist cover defining a cavity. The system further includes an assist assembly at least partially disposed within the cavity. The assist assembly includes a power pack connected to at least one of the rack housing and the assist cover, the power pack having a power pack shaft extending therefrom. The assist assembly also includes a drive pulley having a drive pulley shaft that extends between the rack housing and the assist cover, the drive pulley shaft and the power pack shaft separate shafts and operatively coupled to each other. The assist assembly further includes a driven pulley disposed about the rack member.

Abstract: A method of manufacturing a torsion bar for a steering system is provided. The method includes supporting a torsion bar blank on a cold forming machine with a plurality of dies at a first end region of the torsion bar blank and a second end region of the torsion bar blank. The method also includes rolling the torsion bar blank to form an end region having a cylindrical outer surface extending from an axial end surface and a serrated portion disposed proximate the end region and axially offset from the axial end surface.

Abstract: A power steering system includes a rack housing arranged to receive a longitudinally displaceable rack member. The system also includes an assist cover connected to the rack housing, the rack housing and the assist cover defining a cavity. The system further includes an assist assembly at least partially disposed within the cavity. The assist assembly includes a power pack connected to at least one of the rack housing and the assist cover, the power pack having a power pack shaft extending therefrom. The assist assembly also includes a drive pulley having a drive pulley shaft that extends between the rack housing and the assist cover, the drive pulley shaft and the power pack shaft separate shafts and operatively coupled to each other. The assist assembly further includes a driven pulley disposed about the rack member.

Abstract: A torsion bar for a steering system includes a main body. Also included is an end region having a cylindrical outer surface extending from an axial end surface. Further included is a serrated portion disposed proximate the end region and axially offset from the axial end surface.

Abstract: The invention provides an apparatus including a steering column jacket defining an interior. The invention also provides a bushing disposed in the interior of the steering column jacket. The bushing includes a radially outwardly facing bearing surface and a first channel. The first channel is radially adjacent to the bearing surface. The first channel is accessible from the interior of the steering column jacket. The invention also provides injected filler material disposed in the first channel between the bushing and the steering column jacket. The filler material supports the bearing surface against radial movement relative to the steering column jacket.