A remanufactured pinion shaft includes a salvage member secured to a replacement member. The salvage member may be formed from a damaged pinion shaft and includes first gear teeth proximate a first axial end and a first alignment member proximate a second axial end. The replacement member includes second gear teeth proximate a first axial end and a second alignment member proximate a second axial end. The first alignment member and the second alignment member cooperate to transmit rotational motion between the first salvage member and the replacement member and/or align the salvage member relative to the replacement member.

A remanufactured pinion shaft includes a salvage member secured to a replacement member. The salvage member may be formed from a damaged pinion shaft and includes first gear teeth proximate a first axial end and a first alignment member proximate a second axial end. The replacement member includes second gear teeth proximate a first axial end and a second alignment member proximate a second axial end. The first alignment member and the second alignment member cooperate to transmit rotational motion between the first salvage member and the replacement member and/or align the salvage member relative to the replacement member.

A torsion bar is provided that is easy, quick, and cost effective to manufacture. The torsion bar may extend along an axis and have a first end and a second end that is spaced from the first end. The torsion bar may have an active section positioned between the first and second ends. The active section may also have a length defined along the axis. A cross-section transverse to the axis may define a contour of the torsion bar where the contour may be uniform along the length of the active section. The contour may define at least one of a polygon and a polygon-like shape.

A torsion bar includes a central portion extending in an axial direction about a longitudinal axis. The torsion bar also includes a first end portion having a splined outer surface, the first end portion disposed proximate a first end of the torsion bar, the first end portion spaced from the central portion with a first annular groove extending circumferentially about the torsion bar.

A torsion bar includes a central portion extending in an axial direction about a longitudinal axis. The torsion bar also includes a first end portion having a splined outer surface, the first end portion disposed proximate a first end of the torsion bar, the first end portion spaced from the central portion with a first annular groove extending circumferentially about the torsion bar.

A method of manufacturing a torsion bar is provided. The method includes cutting a stock torsion bar material to a desired torsion bar length to form the torsion bar. The method also includes forming a first end portion by removing material from the torsion bar to form a first annular groove extending circumferentially about the torsion bar. The method further includes forming a second end portion by removing material from the torsion bar to form a second annular groove extending circumferentially about the torsion bar.

A method of manufacturing a torsion bar is provided. The method includes cutting a stock torsion bar material to a desired torsion bar length to form the torsion bar. The method also includes forming a first end portion by removing material from the torsion bar to form a first annular groove extending circumferentially about the torsion bar. The method further includes forming a second end portion by removing material from the torsion bar to form a second annular groove extending circumferentially about the torsion bar.

A method of assembling an electric power steering assembly includes providing a shaft that extends along a longitudinal axis between a first shaft end and a second shaft end. The method further includes extruding or drawing the shaft through a die to define a spline that extends between the first shaft end and the second shaft end. The spline includes a first tooth having a first tip. The method still further includes applying a sleeve over a portion of the spline, such that the sleeve extends from the second shaft end towards the first shaft end.

A method of assembling an electric power steering assembly includes providing a shaft that extends along a longitudinal axis between a first shaft end and a second shaft end. The method further includes extruding or drawing the shaft through a die to define a spline that extends between the first shaft end and the second shaft end. The spline includes a first tooth having a first tip. The method still further includes applying a sleeve over a portion of the spline, such that the sleeve extends from the second shaft end towards the first shaft end.

This torsion beam manufacturing method is a method for manufacturing a torsion beam which is provided with a uniformly shaped closed cross-sectional portion in which a cross section orthogonal to a longitudinal direction is a closed cross section having a substantial V-shape or a substantial U-shape with a pair of ear portions, and a shape changing portion which leads to the uniformly shaped closed cross-sectional portion and in which a shape of the closed cross section changes progressively away from the uniformly shaped closed cross-sectional portion, the torsion beam manufacturing method comprising: thickening to form a pair of thickened portions in at least the shape changing portion by pressurizing each of the pair of ear portions from outside against swelling of the pair of ear portions in a slate where both outer surfaces of each of the pair of ear portions are supported.