Patent ID: 8701259

Claim:
A method of re-manufacturing a shaft-hub assembly to be used in a transfer case, the method comprising the steps of: (a) determining an initial diameter of a journal bearing of a main shaft that has been used in the transfer case; (b) comparing the determined initial diameter to a predetermined minimum threshold; (c) preparing the bearing surface of the journal bearing for a thermal spray process; (d) thermally spraying an aluminum bronze material onto the bearing surface; (e) machining the aluminum bronze material to achieve an outside diameter that provides a desired running clearance with a corresponding finished inside diameter of a central bore for a hub to which the main shaft will be assembled in the transfer case; (f) determining the initial inside diameter of the hub that has been removed from the transfer case; (g) comparing the initial inside diameter to a predetermined maximum threshold; (h) if the initial inside diameter is greater than the predetermined maximum threshold, discarding the hub and using a new hub to mate with the main shaft; and (i) if the initial inside diameter is less than the predetermined maximum threshold, machining the hub to increase the initial inside diameter to the finished inside diameter of the central bore of the hub.