An electric vehicle is provided. The vehicle includes a frame. A battery and a motor may be secured to the frame, such that the battery powers the motor which drives the vehicle. The vehicle may further include at least one axle including a plurality of wheels. A manual steering mechanism including a steering column is operable to pivot the wheels when the steering column is rotated. An overhead frame protrudes vertically from the main frame. A steering drive shaft is supported by the overhead frame and is operable to pivot the wheels when rotated. A head unit is secured to the steering drive shaft and includes a positive electrode and a negative electrode electrically wired to the battery. The head unit is operable to engage an overhead track. The overhead track transfers electrical power to the positive electrode and negative electrode, thereby recharging the battery and driving the motor while steering the electric vehicle.

In a steering system, a first universal joint includes a first yoke coupled to an intermediate shaft. A second universal joint includes a fourth yoke paired with a third yoke coupled to the intermediate shaf and a shaft attachment portion joined to the fourth yoke and in which a bolt insertion hole allowing a pinion shaft to be clamped is formed. When an angle between the intermediate shaf and a steering shaft is set to θ1, an around-axis angle of the first yoke in a rotating direction is set to ω1, and an angle between the intermediate shaft and the pinion shaft is set to θ2, a junction angle between the fourth yoke and the shaft attachment portion in the rotating direction is adjusted to set an around-axis angle of the bolt insertion hole in the rotating direction to a preset angle ω2.

A steering shaft for a motor vehicle includes a hollow outer shaft with a longitudinal axis. An inner shaft is arranged coaxially within the outer shaft. The inner shaft telescopes longitudinally relative to the outer shaft and is connected in a torque-transmitting manner to the outer shaft via a rolling body. The rolling body can roll in the direction of the longitudinal axis and the rolling body bearing in a positively locking manner in the circumferential direction about the longitudinal axis between rolling body raceways on the inner and outer shaft. The steering shaft includes a securing element with a supporting body arranged between supporting faces configured on the inner shaft and on the outer shaft, which at least one supporting body can be supported in a positively locking manner in the circumferential direction. The supporting body is spaced apart in the circumferential direction from the supporting faces.

A steering shaft for a motor vehicle includes a hollow outer shaft with a longitudinal axis. An inner shaft is arranged coaxially within the outer shaft. The inner shaft telescopes longitudinally relative to the outer shaft and is connected in a torque-transmitting manner to the outer shaft via a rolling body. The rolling body can roll in the direction of the longitudinal axis and the rolling body bearing in a positively locking manner in the circumferential direction about the longitudinal axis between rolling body raceways on the inner and outer shaft. The steering shaft includes a securing element with a supporting body arranged between supporting faces configured on the inner shaft and on the outer shaft, which at least one supporting body can be supported in a positively locking manner in the circumferential direction. The supporting body is spaced apart in the circumferential direction from the supporting faces.

In a method of manufacturing an intermediate shaft including: an internal shaft having an external spline; a tubular external shaft having on an inner circumference thereof an internal spline; and a resin coating provided on the external spline, a central axis line of an internal shaft manufacturing intermediate product and a central axis line of an external shaft manufacturing intermediate product are aligned with each other, and the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product are held in such a way that the central axis lines thereof can be adjusted, in a heating adaptation step. In this state, the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product slide relatively in an axial direction. In the heating adaptation step, a grease is interposed between the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product.

In a method of manufacturing an intermediate shaft including: an internal shaft having an external spline; a tubular external shaft having on an inner circumference thereof an internal spline; and a resin coating provided on the external spline, a central axis line of an internal shaft manufacturing intermediate product and a central axis line of an external shaft manufacturing intermediate product are aligned with each other, and the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product are held in such a way that the central axis lines thereof can be adjusted, in a heating adaptation step. In this state, the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product slide relatively in an axial direction. In the heating adaptation step, a grease is interposed between the internal shaft manufacturing intermediate product and the external shaft manufacturing intermediate product.

A steering device (1) installed in a vehicle is equipped with: a steering wheel (10); a steering shaft (20) having a first shaft part (21), one end of which is directly connected to the steering wheel (10), and a second shaft part (22) connected to the first shaft part (21) on the other end side thereof; a coaxial motor (50) which applies a rotational force to the first shaft part (21), and has a motor housing (51) which supports the steering shaft (20) and surrounds the periphery of the first shaft part (21); and a support bracket (60) which extends in the axial direction of the steering shaft (20) in a front region inside the vehicle compartment, is secured to the vehicle compartment on the bottom end side and top end side thereof, and at the top end side thereof, sandwiches the motor housing (51) from both the left and right sides in the vehicle widthwise direction.

A guide member 48 includes a cylindrical portion 52 fitted to a front end of a pinion shaft 19 and extending on the side of an opposite yoke and a slit engagement plate 54 extending on the side of the pinion shaft 19 from a portion, on the side of the pinion shaft 19, of the cylindrical portion 52 and engaging with a slit 42 of a yoke 22, the cylindrical portion 52 being inserted first in a clamp portion 36 of the yoke 22 upon the yoke 22 being fitted to the pinion shaft 19, the yoke 22 being rotatably guided by the cylindrical portion 52.

A guide member 48 includes a cylindrical portion 52 fitted to a front end of a pinion shaft 19 and extending on the side of an opposite yoke and a slit engagement plate 54 extending on the side of the pinion shaft 19 from a portion, on the side of the pinion shaft 19, of the cylindrical portion 52 and engaging with a slit 42 of a yoke 22, the cylindrical portion 52 being inserted first in a clamp portion 36 of the yoke 22 upon the yoke 22 being fitted to the pinion shaft 19, the yoke 22 being rotatably guided by the cylindrical portion 52.

A steering shaft assembly includes a male shaft having a plurality of teeth extending radially outwardly from a portion of the male shaft. The steering shaft assembly also includes a female shaft receiving a portion of the male shaft and fixed to the male shaft in a rotational direction, the male shaft axially moveable relative to the female shaft, the female shaft having an end portion and a body portion, wherein the end portion of the female shaft has an end wall thickness that is less than a body wall thickness of the body portion, the end portion curved radially inwardly to define a hard stop position during axial movement of the male shaft. An end of the plurality of teeth of the male shaft contact the curved end portion of the female shaft at the hard stop position.