Remanufactured pinion shaft and method of making

A remanufactured pinion shaft comprising:

• a salvage member formed at least in part by removing a damaged end of a damaged pinion shaft, the salvage member comprising:
• a first generally cylindrical body extending axially from a first end to a second end, and
• a first plurality of gear teeth proximate the first end, and
• a first alignment member proximate the second end;
• and
• a replacement member secured to the salvage member, the 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, the second alignment member, with the replacement member secured to the salvage member, cooperating with the first alignment member to align the first plurality of gear teeth relative to the second plurality of gear teeth.

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.