Bellows Replacement; Tool List; Pinion Seal Replacement - Cushman Shuttle 2 Service Manual

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
hammer to release tie rod from spindle arm. Remove nut
to drop tie rod from spindle arm.
Unscrew tie rod ball joint and jam nut from threaded
tube.
To install ball joint, first thread on new jam nut and then,
using measurement made earlier, screw ball joint to pre-
vious location in threaded tube. Set jam nut hand tight.
The distance to center of tie rod ball joint from jam nut on both
ends of threaded tube should be the same.
Attach tie rod to spindle. The lock nut (10) should be
tightened to a minimum of 36 ft. lbs. (50 Nm) torque.
Maximum torque is 50 ft. lbs. (70 Nm).
Install front wheel(s) per WHEELS AND TIRES section
and lower vehicle per SAFETY section.
A worn tie rod is likely to have caused incorrect wheel
alignment. Check front wheel alignment and adjust if
necessary. "Wheel Alignment" on page E - 3.
Jam nut should be tightened to 36 - 40 ft. lbs. (49 - 54
Nm) torque.

Bellows Replacement

Tool List

Needle Nose Pliers...................................................... 1
Wrench, 11/16" ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Tape Measure.............................................................. 1
Wrench, 3/4" ................................................................ 1
Wire Cutters................................................................. 1
Wire Tie, 8" Long ......................................................... 1
Torque Wrench, ft. lbs.................................................. 1
Socket, 11/16".............................................................. 1
To replace bellows (1) (Ref Fig. 15), first loosen passen-
ger side front wheel and lift and support front of vehicle
per SAFETY section.
Remove passenger side front wheel and turn steering
wheel fully to the left.
Remove rack ball joint (2) and jam nut (3) from rack
extension (4). "Rack Ball Joint Replacement" on page 10
Cut wire ties (5,6) and slide bellows off rack extension.
Install new bellows aligning small end over groove in
rack extension and secure with new wire tie (5). Leave
Page E-12
NOTICE
Repair and Service Manual
large end loose until rack extension-to-rack and pinion
unit clearance is checked or adjusted.
3
2
5
Fig. 15 Bellows Replacement
Install jam nut (3) and rack ball joint (2) on rack exten-
sion (4) and reattach to spindle arm. "Rack Ball Joint
Replacement" on page 10.
After replacing or servicing steering components, always
verify that an 1/8" gap exists between large hex of rack
extension and rack and pinion unit when steering is
turned fully to the right forcing passenger spindle arm
against front axle.
Check for proper rack extension-to-rack and pinion unit
Qty.
clearance before tightening jam nut (3) to 35 - 45 ft. lbs.
(47 - 61 Nm) torque. "Checking/Adjusting Rack Exten-
sion-to-Rack and Pinion Unit Clearance" on page E - 15.
Install passenger side front wheel per WHEELS AND
TIRES section and lower vehicle per SAFETY section.
Check front wheel alignment and adjust if necessary.
"Wheel Alignment" on page E - 3.

Pinion Seal Replacement

Tool List
Vice ..............................................................................1
Straight Blade Screwdriver, Small................................1
Ball Peen Hammer.......................................................1
Sandpaper, 600 Grit..................................................AR
Shop Towel ...............................................................AR
Wheel Bearing Grease .............................................AR
Socket, 1 1/2"...............................................................1
Secure rack and pinion unit in vice by the mounting ears
only. The rack and pinion unit is made of aluminum and
can be damaged if held otherwise.
1
4
6
Grooves
Qty.