Abstract: A power pack assembly includes a housing extending axially about a longitudinal axis. The power pack assembly also includes a circuit board having a board main portion covered by the housing and having a first board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing. The power pack assembly further includes at least one logic connector disposed on the first board extended segment of the circuit board.

Abstract: A method of assembling a rolling element intermediate shaft assembly includes providing a solid shaft, a tubular shaft, and a wear plate. The solid shaft includes first and second ends. A tubular shaft includes an inner wall with an axially extending groove formed therein. The groove includes an inner surface. The wear plate includes a bottom surface that defines an axially extending channel. The wear plate is orientated in the groove of the tubular shaft with a gap defined by the wear plate and the groove of the tubular shaft. The solid shaft is then inserted into the tubular shaft. At least one ball bearing is inserted within the channel between the wear plate and the solid shaft.

Abstract: A rolling element shaft assembly includes a solid shaft having a first end and a second end, a tubular shaft configured to receive the shaft first end, and a bearing sleeve coupled to the solid shaft. The bearing sleeve includes a first portion defining a first edge, a second edge, and at least one first bearing aperture, and a second portion defining a third edge, a fourth edge, and at least one second bearing aperture. The first portion is configured to couple to the second portion about the solid shaft. The bearing sleeve further includes at least one first bearing disposed within the at least one first bearing aperture and at least one second bearing disposed within the at least one second bearing aperture.

Abstract: A method of assembling a rolling element intermediate shaft assembly includes providing a solid shaft, a tubular shaft, and a wear plate. The solid shaft includes first and second ends. A tubular shaft includes an inner wall with an axially extending groove formed therein. The groove includes an inner surface. The wear plate includes a bottom surface that defines an axially extending channel. The wear plate is orientated in the groove of the tubular shaft with a gap defined by the wear plate and the groove of the tubular shaft. The solid shaft is then inserted into the tubular shaft. At least one ball bearing is inserted within the channel between the wear plate and the solid shaft.

Abstract: A rolling element intermediate shaft assembly includes a solid shaft having first and second ends. Also included is a tubular shaft configured to receive the first end, the tubular shaft having an inner wall with an axially extending groove formed therein, the axially extending groove having an inner surface. Further included is a wear plate having a bottom surface and an elastically deformable body having first and second ends, the body defining an axially extending channel, the body of the wear plate received in the tubular shaft groove. Yet further included is an outer surface of the body of the wear plate defining a gap between the wear plate and the axially extending groove of the tubular shaft, the gap reduced upon flexure of the wear plate. Also included is at least one ball bearing disposed within the wear plate channel between the wear plate and the solid shaft.

Abstract: A 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 rolling element shaft assembly includes a solid shaft having a first end and a second end, a tubular shaft configured to receive the shaft first end, and a bearing sleeve coupled to the solid shaft. The bearing sleeve includes a first portion defining a first edge, a second edge, and at least one first bearing aperture, and a second portion defining a third edge, a fourth edge, and at least one second bearing aperture. The first portion is configured to couple to the second portion about the solid shaft. The bearing sleeve further includes at least one first bearing disposed within the at least one first bearing aperture and at least one second bearing disposed within the at least one second bearing aperture.

Abstract: A rolling element shaft assembly includes a solid shaft having a first end and a second end, a tubular shaft configured to receive the shaft first end, and a bearing sleeve coupled to the solid shaft. The bearing sleeve includes a first portion defining a first edge, a second edge, and at least one first bearing aperture, and a second portion defining a third edge, a fourth edge, and at least one second bearing aperture. The first portion is configured to couple to the second portion about the solid shaft. The bearing sleeve further includes at least one first bearing disposed within the at least one first bearing aperture and at least one second bearing disposed within the at least one second bearing aperture.

Abstract: A rolling element intermediate shaft assembly includes a solid shaft having first and second ends. Also included is a tubular shaft configured to receive the first end, the tubular shaft having an inner wall with an axially extending groove formed therein, the axially extending groove having an inner surface. Further included is a wear plate having a bottom surface and an elastically deformable body having first and second ends, the body defining an axially extending channel, the body of the wear plate received in the tubular shaft groove. Yet further included is an outer surface of the body of the wear plate defining a gap between the wear plate and the axially extending groove of the tubular shaft, the gap reduced upon flexure of the wear plate. Also included is at least one ball bearing disposed within the wear plate channel between the wear plate and the solid shaft.

Abstract: In one aspect, a rolling element shaft assembly is provided. The rolling element shaft assembly includes a solid shaft having a first end and a second end, a tubular shaft configured to receive the shaft first end, and a bearing sleeve coupled to the solid shaft. The bearing sleeve includes a first portion defining a first edge, a second edge, and at least one first bearing aperture, and a second portion defining a third edge, a fourth edge, and at least one second bearing aperture. The first portion is configured to couple to the second portion about the solid shaft. The bearing sleeve further includes at least one first bearing disposed within the at least one first bearing aperture and at least one second bearing disposed within the at least one second bearing aperture.

Abstract: A telescoping shaft having a roller assembly in a steering column is provided. The telescoping shaft includes an outer shaft having at least one projection or at least one groove, and an inner shaft telescopically received in the outer shaft, the inner shaft having the other of the at least one groove and the at least one projection, the at least one groove matingly engaging the at least one projection, each of the at least one grooves having a mounting section formed therein. A roller assembly is positioned in the mounting section of each of the at least one grooves and includes a spring having a first biasing section and a second biasing section, a first plurality of rollers positioned on the first biasing section and a second plurality of rollers positioned on the second biasing section, the at least one projection extending between the first plurality of rollers and the second plurality of rollers.

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 telescoping shaft in a steering column in a steering column is provided. The telescoping shaft includes an outer shaft having a bore extending in a longitudinal direction, an inner shaft telescopically received in the bore, the inner shaft rotationally fixed relative to the outer shaft and moveable relative to the outer shaft in the longitudinal direction, and at least one roller assembly positioned between the inner shaft and outer shaft. Each roller assembly of the at least one the roller assembly includes a spring having a first end and a second end spaced apart from the first end, a first roller positioned on the first end of the spring, and a second roller positioned on the second end of the spring, the spring urging the first roller and the second roller into contact with the outer shaft.

Abstract: A telescoping shaft in a steering column in a steering column is provided. The telescoping shaft includes an outer shaft having a bore extending in a longitudinal direction, an inner shaft telescopically received in the bore, the inner shaft rotationally fixed relative to the outer shaft and moveable relative to the outer shaft in the longitudinal direction, and at least one roller assembly positioned between the inner shaft and outer shaft. Each roller assembly of the at least one the roller assembly includes a spring having a first end and a second end spaced apart from the first end, a first roller positioned on the first end of the spring, and a second roller positioned on the second end of the spring, the spring urging the first roller and the second roller into contact with the outer shaft.

Abstract: A telescoping shaft having a roller assembly in a steering column is provided. The telescoping shaft includes an outer shaft having at least one projection or at least one groove, and an inner shaft telescopically received in the outer shaft, the inner shaft having the other of the at least one groove and the at least one projection, the at least one groove matingly engaging the at least one projection, each of the at least one grooves having a mounting section formed therein. A roller assembly is positioned in the mounting section of each of the at least one grooves and includes a spring having a first biasing section and a second biasing section, a first plurality of rollers positioned on the first biasing section and a second plurality of rollers positioned on the second biasing section, the at least one projection extending between the first plurality of rollers and the second plurality of rollers.

Abstract: A steering column assembly of a vehicle has a rocker-arm lock device for locking an adjustable steering housing and co-extending steering shaft to a stationary bracket or chassis. For driver convenience and comfort, the steering housing and shaft are together adjustable with respect to the bracket. The rocker-arm lock device has a slot in at least one of the housing and bracket and a carrier for longitudinal movement through the slot that is substantially perpendicular to a rotation axis of the steering shaft. An indexing apparatus of the device has first and second indexing rails carried by at least one of the housing and the bracket having the first slot and a carriage engaged rigidly to the carrier. A rocker arm of the apparatus is supported pivotally to the carriage about a rocker axis disposed substantially perpendicular to the carrier.

Abstract: A position control apparatus for a motor vehicle steering column includes an outer bracket, an inner bracket moveable relative to the outer bracket, and a jacket mounted to the inner bracket for telescoping movement along a longitudinal axis and for tilting movement. A first rack is mounted to the inner bracket and extends along the longitudinal axis. A first pinion is rotatable along the first rack during telescoping movement. A second rack is mounted to the outer bracket and extends angularly relative to the longitudinal axis. A second pinion is rotatable along the second rack during tilting movement. The first pinion has a first locking surface and the second pinion has a second locking surface. The first locking surface and the second locking surface may be engaged with each other to prevent telescoping and tilting movement or may be disengaged from each other to allow telescoping and tilting movement.

Abstract: A steering column assembly of a vehicle has a rocker-arm lock device for locking an adjustable steering housing and co-extending steering shaft to a stationary bracket or chassis. For driver convenience and comfort, the steering housing and shaft are together adjustable with respect to the bracket. The rocker-arm lock device has a slot in at least one of the housing and bracket and a carrier for longitudinal movement through the slot that is substantially perpendicular to a rotation axis of the steering shaft. An indexing apparatus of the device has first and second indexing rails carried by at least one of the housing and the bracket having the first slot and a carriage engaged rigidly to the carrier. A rocker arm of the apparatus is supported pivotally to the carriage about a rocker axis disposed substantially perpendicular to the carrier.

Abstract: A position control apparatus for a motor vehicle steering column includes an outer bracket, an inner bracket moveable relative to the outer bracket, and a jacket mounted to the inner bracket for telescoping movement along a longitudinal axis and for tilting movement. A first rack is mounted to the inner bracket and extends along the longitudinal axis. A first pinion is rotatable along the first rack during telescoping movement. A second rack is mounted to the outer bracket and extends angularly relative to the longitudinal axis. A second pinion is rotatable along the second rack during tilting movement. The first pinion has a first locking surface and the second pinion has a second locking surface. The first locking surface and the second locking surface may be engaged with each other to prevent telescoping and tilting movement or may be disengaged from each other to allow telescoping and tilting movement.