Cushman HAULER 800 2012 Technician's Repair And Service Manual page 60

FRONT SUSPENSION AND STEERING
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Check for proper rack extension-to-rack and pinion unit
clearance by first turning steering wheel fully to the right.
The rear spindle arm on the passenger side must rest
against the front axle (Ref Fig. 20). If it does not, all
adjustment is made at the rack ball joint (6) (Ref Fig.
19). Loosen jam nut (5) at rack ball joint and use wrench
to thread shaft of rack extension (7) further into rack ball
joint. This will provide more travel for the steering wheel
to be turned to the right.
Rack
Ball
Joint
Fig. 20 Spindle Contact with Front Axle
With spindle arm resting against front axle, cut wire tie
(14) securing bellows (9) to rack and pinion unit (1) and
slide bellows away from rack and pinion unit to see large
hex of rack extension. An 1/8" gap should exist between
the large hex and the end of the rack and pinion unit.
Fig. 21 Checking Gap
Adjust, using an 1/8" thick washer as a gauge, by turn-
ing shaft of rack extension with wrench to create the 1/8"
gap. Tighten jam nut (5) to 35 - 45 ft. lbs. (47 - 61 Nm)
Page E-16
Passenger Side
Spindle Arm
Resting Against
Front Axle
Approximately
1/8" Thick Washer
Gap
Repair and Service Manual
torque. Secure bellows to rack and pinion unit with new
wire tie (14).
Steering Wheel Replacement
Tool List
Socket, 15/16"..............................................................1
Ratchet, 1/2" drive .......................................................1
Plastic Faced Hammer ................................................1
Ball Peen Hammer.......................................................1
Front
of Vehicle
Anti-seize Compound ..................................................1
Torque Wrench, ft. lbs. .................................................1
To maintain correct orientation when replacing steering wheel,
first turn wheels straight ahead.
To prevent damage to the clipboard, perform the following
removal procedure. Do not use a screwdriver to push or
pry the retaining tabs.
From the front side of the steering wheel (4), remove the
clipboard (5) by first pulling straight up on the bottom of
the clipboard to release the two bottom retaining tabs.
Then, using thumb for leverage as shown, reach from
behind steering wheel with fingertips to first pull down,
and then push up to release the two top clipboard retain-
ing tabs (Ref Fig. 22).
Loosen the steering wheel retaining nut (6) two to three
turns (Ref Fig. 23). DO NOT REMOVE NUT AT THIS
TIME. Apply upward pressure to the steering wheel.
Place a plastic faced hammer against the steering wheel
nut and strike plastic faced hammer sharply with a ball
peen hammer.
NOTICE
4
5
Step 1
Fig. 22 Clipboard Removal
Qty.
Step 2