Power transfer assemblies for motor vehicle drivelines having integrated two-piece pinion shaft and coupling unit

A method of assembling a pinion-bearing-coupling (PBC) unit, the PBC unit facilitating the transfer of drive torque from a rotary input to a rotary output in a motor vehicle, the method comprising the steps of:

• providing a coupler including a coupler shaft having an outer surface defining a first cylindrical surface and an first inner race surface;
• providing a pinion unit having an outer surface defining a second inner race surface;
• providing a bearing unit including a lock collar and a bearing ring, the bearing ring having an inner surface defining a first outer race surface including at least one respective first roller and a second outer race surface including at least one respective second roller;
• mounting the pinion unit to the coupler shaft to establish a press-fit relationship;
• installing the bearing unit such that the at least one first roller engages the first inner race surface and the first outer race surface and the at least one second roller engages the second inner race surface and the second outer race surface;
• and
• displacing the lock collar for moving the bearing ring so as to adjust the preload applied to the at least one first roller and the at least one second roller.

A power transfer assembly for use in a motor vehicle, comprising:

• a rotary input driven by a powertrain;
• a rotary output arranged to transfer drive torque to a set of wheels;
• an integrated pinion-bearing-coupling (PBC) assembly is drivingly interconnected to one of said rotary input and said rotary output for facilitating the transfer of drive torque from said rotary input to said rotary output;
• and
• wherein said integrated PBC assembly includes a coupler unit, a pinion unit and a bearing unit, said coupler unit including a coupler flange segment and a tubular coupler shaft segment, said tubular coupler shaft segment including an exterior surface defining an inner race surface and an annular rim, said bearing unit including an outer surface defining at least one outer race surface, at least one roller disposed between said inner race surface and said at least one outer race surface, a pinion unit including an interior surface defining a receiver surface including at least one of a groove and a projection in fixed engagement with said annular rim.