Rack And Pinion Unit Disassembly And Inspection; Front Of Vehicle - 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

Front of Vehicle

9
10
4
Fig. 18 Spindle Replacement
The thrust washer (9) is located on top of spindle between
spindle and front axle.
Tighten new lock nut (5) to 56 - 70 ft. lbs. (75 - 95 Nm)
torque. Check that spindle turns freely on king pin tube
after tightening.
Tighten lock nut (2) to 36 ft. lbs. (50 Nm). Maximum
torque is 50 ft. lbs. (70 Nm).
Install front wheels 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.
Rack and Pinion Unit Disassembly and
Inspection
Tool List
Vice.............................................................................. 1
Socket, 3/8" ................................................................. 1
Ratchet ........................................................................ 1
Wrench, 11/16" ............................................................ 1
Wrench, 3/4" ................................................................ 1
Wire Cutter .................................................................. 1
Retaining Ring Pliers ................................................... 1
Shop Towel ............................................................... AR
CITGO Lithoplex MP No. 2 grease........................... AR
Wire Tie, 8" Long ......................................................... 1
Page E-14
2
6
8
7
3 5
NOTICE
Repair and Service Manual
Wire Tie, 10" Long .......................................................1
Torque Wrench, in. lbs. ................................................1
The rack and pinion gears are not serviceable items. If they
are found to be damaged or excessively worn, a new rack and
pinion unit must be installed.
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.
Remove rack and pinion unit from vehicle. Anchor in
vice by clamping on the mounting ears of the unit.
Disassemble rack and pinion unit (1) by first removing
screw (13) and tensioner (2) to relieve pressure on rack
(3) and pinion (4) (Ref Fig. 19). Loosen jam nut (5) and
remove rack ball joint (6) from rack extension (7). Cut
wire ties (8, 14) securing bellows (9) and slide bellows
off rack extension. Pull rack (3) from unit (1). Remove
pinion seal (10). "Pinion Seal Replacement" on page E -
12 Remove internal retaining ring (11) from rack and pin-
ion unit and pull out pinion (4) and ball bearing (12) as
an assembly.
5
6
8
Qty.
Fig. 19 Rack and Pinion Unit Disassembly
Clean rack, pinion and housing. Inspect gear teeth,
bearing surfaces and grease seal surfaces of rack and
pinion for excessive wear or damage. If any is found, the
rack and pinion unit must be replaced as an assembly.
"Rack and Pinion Unit Replacement" on page E - 15
NOTICE
9
13
7
3
14
11
10
2
1
4
12