Abstract: A method of manufacturing a steering shaft assembly includes inserting an inner shaft into an outer shaft along a longitudinal axis. The method further includes placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

Abstract: A method of manufacturing a steering shaft assembly includes heating an inner shaft and heating an outer shaft. The method also includes applying a plastic coating to at least a portion of the inner shaft. The method further includes cooling the plastic coating and pressing the outer shaft and the inner shaft together.

Abstract: A method of manufacturing a steering shaft assembly includes inserting an inner shaft into an outer shaft along a longitudinal axis. The method further includes placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

Abstract: A method of manufacturing a steering shaft assembly includes inserting an inner shaft into an outer shaft along a longitudinal axis. The method further includes placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

Abstract: A method of manufacturing a steering shaft assembly includes inserting an inner shaft into an outer shaft along a longitudinal axis. The method further includes placing the inner shaft and the outer shaft into a tool having a staking tool provided with a staking feature; aligning a stake with a base of a tooth of the plurality of fine teeth of the outer shaft; and pressing the stake axially into an outer shaft first end to a predetermined depth using the staking feature.

Abstract: A method of manufacturing a steering shaft assembly includes heating an inner shaft and heating an outer shaft. The method also includes applying a plastic coating to at least a portion of the inner shaft. The method further includes cooling the plastic coating and pressing the outer shaft and the inner shaft together.

Abstract: A steering shaft assembly is disclosed with an outer shaft operatively connected to a one of a steered member or a steering control. The outer shaft has an open end and a receiving chamber associated with the open end. The steering shaft assembly also includes an inner shaft operatively connected to another of the steered member or the steering control. The inner shaft has an engaging portion axially slideably received in the outer shaft receiving chamber. The inner shaft engaging portion also includes a polymer coating disposed on an outer surface of the inner shaft engaging portion. The coating has an outer surface that slideably engages with a surface of the outer shaft receiving chamber, and which has comprises projections and recesses along the coating outer surface.

Abstract: A steering shaft assembly is disclosed with an outer shaft operatively connected to a one of a steered member or a steering control. The outer shaft has an open end and a receiving chamber associated with the open end. The steering shaft assembly also includes an inner shaft operatively connected to another of the steered member or the steering control. The inner shaft has an engaging portion axially slideably received in the outer shaft receiving chamber. The inner shaft engaging portion also includes a polymer coating disposed on an outer surface of the inner shaft engaging portion. The coating has an outer surface that slideably engages with a surface of the outer shaft receiving chamber, and which has comprises projections and recesses along the coating outer surface.

Abstract: A universal joint assembly includes a hollow upper shaft, a lower shaft extending at least partially within the upper shaft, and a cage having a plurality of bearing apertures. Each bearing aperture includes a pair of opposed loading pads having a distinct inner wall surface sector extending radially inward into the at least one bearing aperture. The cage receives at least a portion of the lower shaft and is positioned within the hollow upper shaft. The assembly further includes at least one upper tilt pin extending through the upper shaft and a bearing aperture of the plurality of bearing apertures, and a lower tilt pin extending through the lower shaft and a bearing aperture of the plurality of bearing apertures.

Abstract: A universal joint assembly includes a hollow upper shaft having an inner surface, a lower shaft extending at least partially within the upper shaft, and a cage receiving at least a portion of the lower shaft, the cage positioned within the hollow upper shaft. The assembly further includes at least one upper tilt pin extending through the upper shaft and the cage, at least one groove formed in the inner surface of the upper shaft, and a lower tilt pin extending through the cage and the lower shaft. The lower tilt pin extends into the at least one groove.

Abstract: In another aspect of the invention, a universal joint assembly is provided. The assembly includes a hollow upper shaft, a lower shaft extending at least partially within the upper shaft, and a cage having a plurality of bearing apertures. Each bearing aperture includes a pair of opposed loading pads having a distinct inner wall surface sector extending radially inward into the at least one bearing aperture. The cage receives at least a portion of the lower shaft and is positioned within the hollow upper shaft. The assembly further includes at least one upper tilt pin extending through the upper shaft and a bearing aperture of the plurality of bearing apertures, and a lower tilt pin extending through the lower shaft and a bearing aperture of the plurality of bearing apertures.

Abstract: In an embodiment of the invention, a universal joint assembly is provided. The assembly includes a hollow upper shaft having an inner surface, a lower shaft extending at least partially within the upper shaft, and a cage receiving at least a portion of the lower shaft, the cage positioned within the hollow upper shaft. The assembly further includes at least one upper tilt pin extending through the upper shaft and the cage, at least one groove formed in the inner surface of the upper shaft, and a lower tilt pin extending through the cage and the lower shaft. The lower tilt pin extends into the at least one groove.