Abstract: A steering column assembly is provided. The assembly includes an outer jacket, an inner jacket telescopingly disposed within the outer jacket for movement along a longitudinal axis with a cavity defined between the inner and outer jackets. A bushing is radially disposed about the inner jacket within the cavity between the inner and outer jackets. The bushing includes at least one tab engaging the inner jacket to interconnect the bushing to the inner jacket and includes at least one radially projecting pad engaging the outer jacket to frictionally interconnect the bushing to the outer jacket for interlocking the inner and outer jackets.

Abstract: A steering column assembly is provided. The assembly includes an outer jacket, an inner jacket telescopingly disposed within the outer jacket for movement along a longitudinal axis with a cavity defined between the inner and outer jackets. A bushing is radially disposed about the inner jacket within the cavity between the inner and outer jackets. The bushing includes at least one tab engaging the inner jacket to interconnect the bushing to the inner jacket and includes at least one radially projecting pad engaging the outer jacket to frictionally interconnect the bushing to the outer jacket for interlocking the inner and outer jackets.

Abstract: A method of manufacturing a steering column assembly having a first jacket and a second jacket with a bushing between the first and second jackets. The method utilizes a manufacturing machine having a loadable member, a fixed member, and a thermal fixture. The method comprises the steps of: assembling the first jacket to the second jacket with the bushing located radially between the first and second jackets to interlock the first and second jackets and prevent axial movement between the first and second jackets; connecting the first jacket to the loadable member of the manufacturing machine; connecting the second jacket to a fixed member of the manufacturing machine; loading the loadable member to apply an axial force to the first jacket; heating the thermal fixture of the manufacturing machine; and melting the bushing until the first jacket moves axially relative to the second jacket.

Abstract: A method for delashing a shaft assembly and an assembly embodying the method are disclosed. The assembly includes a housing having a bore extending therethrough, and a shaft mounted within the bore. A shoulder extends into the bore to define a constriction along the bore. A bushing is positioned on an end of the shaft such that at least a portion of the bushing is spaced apart from the shoulder to define a cavity therebetween when the shaft is in the bore. A filler material is disposed in the cavity between the bushing and the shoulder for maintaining an axial compressive load on the shaft. In another aspect, a plug formed from a fusible material is provided. The plug includes a base portion and a plurality of channels disposed along an exterior of the base portion for enabling a flow of melted plug material along the channels.

Abstract: A telescoping steering column assembly and method of manufacturing the assembly are disclosed. The assembly includes an outer jacket defining at least one hole and a central axis. An inner jacket is disposed in the outer jacket and slides relative to the outer jacket along the central axis. A plug having a body portion and a flange extending radially outwardly from the body portion is disposed in the hole of the outer jacket. The plug defines at least one channel and the plug is heated to create a molten material that flows into the channel of the plug for securing the plug within the hole to prevent movement of the plug along the central axis and for aligning the inner jacket within the outer jacket to allow the inner jacket to slide within the outer jacket.

Abstract: A method of manufacturing a steering column assembly having a first jacket and a second jacket with a bushing between the first and second jackets. The method utilizes a manufacturing machine having a loadable member, a fixed member, and a thermal fixture. The method comprises the steps of: assembling the first jacket to the second jacket with the bushing located radially between the first and second jackets to interlock the first and second jackets and prevent axial movement between the first and second jackets; connecting the first jacket to the loadable member of the manufacturing machine; connecting the second jacket to a fixed member of the manufacturing machine; loading the loadable member to apply an axial force to the first jacket; heating the thermal fixture of the manufacturing machine; and melting the bushing until the first jacket moves axially relative to the second jacket.

Abstract: A method for delashing a shaft assembly and an assembly embodying the method are disclosed. The assembly includes a housing having a bore extending therethrough, and a shaft mounted within the bore. A shoulder extends into the bore to define a constriction along the bore. A bushing is positioned on an end of the shaft such that at least a portion of the bushing is spaced apart from the shoulder to define a cavity therebetween when the shaft is in the bore. A filler material is disposed in the cavity between the bushing and the shoulder for maintaining an axial compressive load on the shaft. In another aspect, a plug formed from a fusible material is provided. The plug includes a base portion and a plurality of channels disposed along an exterior of the base portion for enabling a flow of melted plug material along the channels.

Abstract: A vehicle chassis is a shaped metal sheet chassis body or member with regions of relatively low torsional rigidity, and regions of relatively higher torsional rigidity. At least some of the low torsional rigidity regions are reinforced with a composite overlay comprising directionally oriented long fibers of carbon or the like which may be woven into a mat of directionally oriented fibers and embedded in a matrix of resin or the like. The overlay increases the regions of the chassis to which is applied without significantly increasing the weight of the chassis.

Abstract: A process for manufacturing polymer/metal disks in a single piece batch size comprises applying a bonding agent to a metallic hub, pressing a polymeric ring over the metallic hub to form a ring/hub assembly, and heating the ring/hub assembly to cause bonding to occur between the polymeric ring and the metallic hub. The bonding agent may either be sprayed or applied directly to the metallic hub. Other methods of application may also be employed, such as dipping of the metallic hub in the bonding agent. The bonding agent is generally an organosilane, although other compounds capable of bonding a polymer to a metallic substrate can be used. The pressing of the polymeric ring over the metallic hub comprises enlarging the polymeric ring and mounting it over the metallic hub. The enlargement of the polymeric ring is typically effectuated either with heat or by stretching.

Abstract: A gear assembly includes a dampening layer disposed intermediate to a face and a backing. The dampening layer is preferably injection molded between the face and the backing through one or more openings in the backing. The dampening layer minimizes noise and vibrations associated with gear assemblies and interfaces and reduces the transmission of noise and vibrations through the gear assembly.

Abstract: A ring assembly manufacturing apparatus (30) and method provides heat to a ring (216) such as a polymeric ring from an infrared source (48). A ring assembly (214) includes a ring (216) and a hub (218) within the ring. The ring (216) is traversed into a chamber (46) such that the ring (216) is exposed to infrared energy from the infrared source (48). The infrared energy causes the ring (216) to expand thereby facilitating assembly with the hub (218).

Abstract: A variable effort automotive power steering gear including an input or stub shaft, an output shaft or pinion head, a torsion bar between the stub shaft and pinion head defining an open-center position of one relative to the other, and detent reaction apparatus between the stub shaft and pinion head. The detent reaction apparatus includes a radial socket in a cylindrical wall of the pinion head, a detent groove in a stem of the stub shaft in the cylindrical wall, an insert rotatably supported in the radial socket with an eccentric bore offset from the centerline of the radial socket, and a detent element slidably supported in the eccentric bore in the insert and having a spherical end adapted to seat in the detent groove. The spherical end of the detent element is centered in the detent groove by rotating the insert until the detent element is at an innermost radial position.