Remanufactured pinion shaft and method of making

1. A method of remanufacturing a pinion shaft comprising:

providing a pinion shaft comprising a first generally cylindrical body extending axially from a first end to a damaged end, the pinion shaft further comprising a plurality of first gear teeth proximate the first end,

cutting the pinion shaft at a position between the first end and the damaged end to form a salvage member comprising the first end, the plurality of first gear teeth, and a second end spaced axially from the first end;

forming, on the salvage member proximate the second end, an axial protrusion;

providing a replacement member comprising a second generally cylindrical body extending axially from a third end to a fourth end, a second plurality of gear teeth proximate the third end, and a receptacle proximate the fourth end; and

securing the salvage member to the replacement member such that the axial protrusion is received in the receptacle.

2. The method of claim 1 , further comprising:

forming a plurality of splines on the axial protrusion,

wherein the replacement member further comprises a plurality of grooves formed in the receptacle, the grooves being sized and positioned to receive the plurality of splines with the salvage member secured to the replacement member.

3. The method of claim 1 , wherein a first outer diameter of the first generally cylindrical body is substantially the same as a second outer diameter of the second generally cylindrical body.

4. The method of claim 1 , further comprising:

forming a first alignment member on the axial protrusion,

wherein the replacement member comprises a second alignment member, and

wherein the first alignment member and the second alignment member cooperate to position the first plurality of gear teeth relative to the second plurality of gear teeth with the salvage member secured to the replacement member.

5. The method of claim 4 , wherein the first alignment member and the second alignment member comprise at least one of:

a key and a channel configured to receive the key;

a spline and groove arrangement; or

a non-circular cross-section of the axial protrusion and the receptacle.

6. The method of claim 1 , wherein the replacement member comprises:

a first replacement portion comprising the second plurality of gear teeth; and

a second replacement portion separate from and configured to mate with the first replacement portion, the second replacement portion comprising the receptacle, the method further comprising:

securing the first replacement portion to the second replacement portion to form the replacement member.

7. The method of claim 6 , wherein:

the second replacement portion comprises a third substantially cylindrical body extending axially from the fourth end to a fifth end opposite the fourth end,

the receptacle comprises an opening extending axially through the third substantially cylindrical body from the fourth end to the fifth end,

the first replacement portion comprises a fourth substantially cylindrical body including the third end and a sixth end opposite the third end, the first replacement portion having a second axial protrusion, at the sixth end, sized to be received in the opening proximate the fifth end, and

the securing the first replacement portion to the second replacement portion comprises coupling the first replacement portion to the second replacement portion such that the second axial protrusion of the first replacement member is disposed in the opening proximate the fifth end of the second replacement portion.

8. The method of claim 7 , wherein:

the first replacement portion comprises a first alignment member on the second axial protrusion and the second replacement portion comprises a second alignment member in the receptacle, and

the securing the first replacement portion to the second replacement portion comprises aligning the first alignment member relative to the second alignment member to position the second gear teeth relative to a third alignment feature disposed in the opening proximate the fourth end of the cylindrical body.

9. A method of making a remanufactured pinion shaft comprising:

providing a pinion shaft comprising a first generally cylindrical body extending axially from a first end to a damaged end, the pinion shaft further comprising a plurality of first gear teeth proximate the first end,

cutting the pinion shaft at a position between the first end and the damaged end to form a salvage member comprising the first end, the plurality of first gear teeth, and a second end spaced axially from the first end;

forming, on the salvage member proximate the second end, a first alignment member;

providing a replacement member comprising a second generally cylindrical body extending axially from a third end to a fourth end, a second plurality of gear teeth proximate the third end, and a second alignment member proximate the fourth end; and

securing the salvage member to the replacement member such that the first alignment member cooperates with the second alignment member to align the plurality of first gear teeth relative to the plurality of second gear teeth.

10. The method of claim 9 , wherein the first alignment member and the second alignment member comprise at least one of:

one or more splines and one or more grooves configured to receive the one or more splines;

a key and a channel configured to receive the key; or

a protrusion comprising other than a circular cross-section and a receptacle configured to receive the protrusion.

11. The method of claim 9 , wherein the securing the salvage member to the replacement member comprises welding the salvage member to the replacement member.

12. The method of claim 9 , wherein the providing the replacement member comprises:

providing a first replacement portion comprising the second plurality of gear teeth; and

providing a second replacement portion separate from and configured to mate with the first replacement portion, the second replacement portion comprising the second alignment member, the method further comprising:

securing the first replacement portion to the second replacement portion to form the replacement member.

13. The method of claim 12 , wherein:

the second replacement portion comprises a third substantially cylindrical body extending axially from the fourth end to a fifth end opposite the fourth end;

an opening extends axially through the third substantially cylindrical body from the fourth end to the fifth end;

the opening defines an interior surface; and

the second alignment member comprises a plurality of grooves formed in the interior surface.

14. The method of claim 13 wherein:

the first alignment member comprises a first plurality of splines configured to be received in the plurality of grooves; and

the first replacement portion comprises a second plurality of splines configured to be received in the plurality of grooves.