Cushman HAULER 800 2012 Technician's Repair And Service Manual page 57

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
To access the pinion seal, remove rack and pinion unit
from vehicle. "Rack and Pinion Unit Replacement" on
page E - 15 Anchor in vice by clamping on the mounting
ears of the rack and pinion unit.
Slide a small straight blade screwdriver between lip of
seal and pinion and pry top portion of seal up to remove
(Ref Fig. 16).
Fig. 16 Pinion Seal Replacement
Use screwdriver to lift inner portion of seal up and off
pinion.
Check pinion surface for roughness and sand lightly if
needed.
NOTICE
Wipe bore clean and lubricate pinion and lip of seal with
grease.
The bore has a positive stop to correctly locate the seal during
installation.
Place seal over pinion and tap carefully with socket and
hammer to start seal straight in bore. Drive seal fully into
bore until it stops and wipe clean of any excess grease.
Attach rack and pinion unit to front axle. "Rack and Pin-
ion Unit Replacement" on page E - 15.
Spindle Replacement
Tool List
Needle Nose Pliers...................................................... 1
Wrench, 11/16" ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Wrench, 3/4"................................................................ 1
Socket, 3/4" ................................................................. 1
Socket, 11/16" ............................................................. 1
Torque Wrench, ft. lbs. ................................................ 1
FRONT SUSPENSION AND STEERING
The spindle bearings are designed to be used "dry".
Lubrication attracts dirt and will ruin the bearings. Do not
apply grease to the spindle bearings.
Loosen front wheel. Lift and support front of vehicle per
SAFETY section and remove front wheel.
If vehicle is equipped with front disc brakes, remove cal-
iper by removing bolts (1) and washers (2). Secure the
caliper with a length of wire, cord or wire tie to relieve
any tension that would be created by the caliper hanging
Lip of
Seal
from the brake line.
To remove tie rod, loosen lock nut (2) until tie rod ball
joint (3) threads are protected (Ref Fig. 18). Using a ball
joint separator as a lever, apply pressure to ball joint and
tap nut with plastic faced hammer to release tie rod from
spindle arm (4). Remove nut from tie rod and tie rod
from spindle arm.
If removing passenger side spindle, repeat previous
step for rack ball joint.
Qty.
Remove lock nut (5) and washer (7) from bolt (6) and
discard nut. Pull bolt (6) and washer (8) from spindle
and separate spindle from axle. Remove thrust washer
(9) and king pin tube (10) from spindle.
Spindle installation is the reverse order of disassembly.
Repair and Service Manual
1
2
Fig. 17 Removing Brake Caliper
B
B
Page E-13