Intermediate shaft axial retention device

A method of manufacturing a steering shaft assembly comprising:

• axially inserting an end region of a female shaft into a stake forming tool aperture of a stake forming tool;
• stopping axial insertion of the end region into the stake forming tool aperture with a step to prevent insertion of a splined portion of the female shaft into the stake forming tool aperture;
• forming a plurality of stakes within the end region of the female shaft to provide a retention feature on the female shaft for a male shaft inserted therein, wherein each of the plurality of the stakes extend radially inwardly;
• and
• forming a plurality of spline ends on a plurality of splines of the male shaft at an angle relative to a longitudinal direction of the splines that is greater than a stake angle to prevent wedging of the male shaft and the female shaft, wherein each of the spline ends is an axial end and contacts an inner wall of one of the plurality of stakes to define an interface between the stakes and the spline ends as a hard stop interface, wherein the hard stop interface is formed by an interior surface of the female shaft.