Patent ID: 7207231

Claim:
A method of forming a rack for a rack and pinion steering system, said method comprising the steps of: providing a hollow tube having an axis, a first end portion, and a second end portion, the second end portion of the tube being adapted for connection with first vehicle steering linkage, such as a first tie rod, the first end portion being open; closing a die assembly on the open first end portion of the tube to form a die cavity extending axially from the first end portion of the tube, the die assembly having internal rack tooth forms; placing a quantity of powder metal in the die assembly and tube so that a first part of the powder metal extends into the open first end portion of the tube and a second part of the powder metal extends outward from the first end portion of the tube in the die cavity; compressing the powder metal in the die cavity and in the first end portion of the tube to form a fully dense powder metal rack tooth section of the rack, the rack tooth section having a plurality of external rack teeth formed by the internal rack tooth forms of the die assembly; and sintering the powder metal rack tooth section of the rack.