Abstract: A method of fabricating a driveline assembly including the steps of inserting a first member within a second member, heating the first member to a temperature greater than that of the second member and inserting both members into a die. The inner surface of the die includes an interlocking torque transferring profile. Fluid pressure is applied to the inner diameter of the inner member to expand both members into the profile on the inner surface of the die. The inner and outer members are then removed from the die and cooled such that both members are at a common temperature. Because the inner member was at an elevated temperature, and thereby expanded a greater amount than the outer member, cooling of the members results in a clearance between the members that provides for relative axial movement between the inner and outer members.

Abstract: A method of fabricating a driveline assembly including the steps of inserting a first member within a second member, heating the first member to a temperature greater than that of the second member and inserting both members into a die. The inner surface of the die includes an interlocking torque transferring profile. Fluid pressure is applied to the inner diameter of the inner member to expand both members into the profile on the inner surface of the die. The inner and outer members are than removed from the die and cooled such that both members are at a common temperature. Because the inner member was at an elevated temperature, and thereby expanded a greater amount than the outer member, cooling of the members results in a clearance between the members that provides for relative axial movement between the inner and outer members.

Abstract: A driveline assembly including first and second members disposed along an axis and an intermediate member engaged to the first and second members along the axis such that the first, second, and intermediate members move axially relative to each other. The first and second members include an interconnection with the intermediate member to transmit torque from the first member through the intermediate member to the second member. The interconnection between the members is formed by interlocking profiles disposed on the outer diameter of the first and second members that corresponds to an interlocking profile on the inner diameter of the intermediate member. The interconnection between the first and second members with the intermediate member includes a sleeve to substantially fill any gaps to prevent relative rotation between the members.