Abstract: An intermediate shaft assembly and method of assembly thereof. The intermediate shaft assembly includes a first shaft extending between a first end and a second end. The first shaft has a tubular wall portion with an inner surface bounding a hollow bore extending into said first end. The inner surface has a plurality of female splines and the tubular wall portion has at least one through opening. A second shaft extends between a coupling end and a connection end. The connection end has an outer surface sized for a clearance fit within the hollow bore. The outer surface has a plurality of male splines configured for an interdigitated fit with the female splines. The interdigitated fit establishes a clearance gap between the male splines and the female spines. A polymeric material at least partially fills the clearance gap and extends into the at least one through opening.

Abstract: An intermediate shaft assembly and method of assembly thereof are provided. The intermediate shaft assembly includes a first shaft extending between a first end and a second end. The first shaft has a tubular wall portion with an inner surface bounding a hollow bore extending into said first end. The inner surface has a plurality of female splines and the tubular wall portion has at least one through opening. A second shaft extends between a coupling end and a connection end. The connection end has an outer surface sized for a clearance fit within the hollow bore. The outer surface has a plurality of male splines configured for an interdigitated fit with the female splines. The interdigitated fit establishes a clearance gap between the male splines and the female spines. A polymeric material at least partially fills the clearance gap and extends into the at least one through opening.