Abstract: In one aspect, a rolling element intermediate shaft assembly is provided. The assembly includes a solid shaft having a first end and a second end and a tubular shaft configured to receive the shaft first end. The tubular shaft includes an inner wall with an axially extending groove formed therein, and the axially extending groove includes an inner surface. The assembly further includes a wear plate having a bottom surface and defining an axially extending channel, the wear plate being received in the tubular shaft axially extending groove, and at least one ball bearing disposed within the wear plate channel between the wear plate and the solid shaft.

Abstract: In one aspect, a solid shaft sub-assembly is provided. The solid shaft sub-assembly includes a solid shaft having a first portion and a second portion, and a yoke including an inner wall defining an aperture to receive the solid shaft. The aperture has a non-circular first cross-sectional profile, and the solid shaft first portion is positioned within the aperture and is deformed such that the first portion is formed with a second cross-sectional profile complementary to the first cross-sectional profile to axially and torsionally couple the solid shaft to the yoke.

Abstract: A steering system having a pinion and an input shaft is disclosed. The pinion includes an outer surface and at least one pinion stop tooth located along the outer surface. The at least one pinion stop tooth has a pair of pinion pressure surfaces. The input shaft defines a recess configured for receiving the pinion. The input shaft includes an inner surface located within the recess and at least one shaft stop tooth located along the inner surface. The at least one shaft stop tooth has a pair of shaft pressure surfaces. A specific shaft pressure surface is positioned to generally oppose a specific pinion pressure surface, and the specific shaft pressure surface and the specific pinion pressure surface are generally parallel to one another.