Knuckle-supported wheelend assembly with improved shaft-hub interface

A wheelend assembly for a corner module of a motor vehicle, wherein the corner module includes a knuckle having a bore adapted to receive and support the wheelend assembly, the wheelend assembly comprising:

• a shaft having an inboard end, an outboard end, and a longitudinal axis, wherein one of the inboard end and the outboard end includes a radial flange, and wherein the shaft further includes a contoured peripheral surface portion proximate to the outboard end, the contoured surface portion including at least three crests when viewed in lateral cross-section, each crest having a maximum crest diameter that remains substantially constant over a first length of the shaft;
• a bearing assembly supporting the shaft for rotation in the bore of the knuckle, the bearing assembly including a pair of inner races respectively defining a bearing face generally normal to the longitudinal axis of the shaft, one bearing face abutting the radial flange of the shaft;
• and
• a hub mounted on the shaft proximate to the outboard end, wherein the hub includes an outboard wheel-mounting face and an inboard face, the inboard face of the hub directly abutting the other bearing face, and wherein the hub includes a central portion with a central bore adapted to matingly receive the contoured peripheral surface portion of the shaft such that the hub rotates with the shaft;
• and
• a threaded fastener engaging one of the inboard end and the outboard end of the shaft, the fastener axially biasing the hub towards the radial flange,
• wherein the central bore of the hub engages the contoured peripheral surface portion of the shaft along a second length of the shaft within the first length, and wherein each crest of the contoured peripherel surface portion of the shaft includes a circumferential jog along a third length of the shaft within the second length, the third length being no greater than about 30% of the second length.