Rack And Pinion Unit Replacement; Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
If rack and pinion pass inspection, clean them, tensioner
and housing thoroughly and lubricate for assembly. Use
grease specified in tool list.
Assemble rack and pinion unit by first installing pinion in
reverse order of removal making sure to lubricate pinion
seal lip prior to installing seal. "Pinion Seal Replace-
ment" on page E - 12 Insert rack into rack and pinion
unit. Turn pinion clockwise to help pull rack in if neces-
sary. Install bellows and secure to rack extension with
wire tie (8). Do not secure large end of bellows to rack
and pinion unit until instructed to do so after setting
proper rack extension-to-rack and pinion unit clearance.
Install tensioner and tighten bolts (13) to 100 - 120 in.
lbs. (11 - 14 Nm) torque. Thread jam nut and rack ball
joint to original location on rack extension and set jam
nut hand tight.
Install rack and pinion unit on vehicle. "Rack and Pinion
Unit Replacement" on page E - 15.
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.
Set proper rack extension-to-rack and pinion unit clear-
ance. "Checking/Adjusting Rack Extension-to-Rack and
Pinion Unit Clearance" on page E - 15.

Rack and Pinion Unit Replacement

Tool List
Socket, 13 mm ............................................................ 1
Ratchet ........................................................................ 1
Needle Nose Pliers...................................................... 1
Wrench, 11/16" ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Wrench, 5/8"................................................................ 1
Socket, 5/8" ................................................................. 1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs. ................................................ 1
Socket, 11/16" ............................................................. 1
Torque Wrench, in. lbs................................................. 1
To remove rack and pinion unit (12) (Ref Fig. 12), loosen
front wheels and lift and support front of vehicle per
SAFETY section. Remove front wheels.
Remove bolt (13) and washer (14) securing intermediate
shaft (15) to rack and pinion unit (12).
FRONT SUSPENSION AND STEERING
Remove cotter pin (2) and loosen castellated nut (3)
until rack ball joint (1) threads are protected. Using a ball
joint separator as a lever, apply pressure to ball joint and
tap nut with plastic faced hammer to release ball joint
from passenger side spindle arm. Remove nut from ball
joint and ball joint from spindle arm.
Remove the three lock nuts (18) securing rack and pin-
ion unit to front axle and discard nuts. The rack and pin-
ion unit can now be removed from vehicle. Retain
washers (19), spacers (20) and the two bolts (16) for
assembly.
Replace rack and pinion unit in reverse order of
removal.
Use new lock nuts (18) and tighten them to 35 - 50 ft.
lbs. (50 - 70 Nm) torque.
Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque
and continue to tighten as needed to insert new cotter
pin. Maximum torque is 50 ft. lbs. (70 Nm).
Tighten bolt (13) securing intermediate shaft to pinion to
155 - 215 in. lbs. (18 - 24 Nm) torque.
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.
Set proper rack extension-to-rack and pinion unit clear-
ance. "Checking/Adjusting Rack Extension-to-Rack and
Qty.
Pinion Unit Clearance" on page E - 15.
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.
Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance
Tool List
Wrench, 11/16" ............................................................1
Wrench, 3/4" ................................................................1
Wrench, 1/2" ................................................................1
Wire Cutter...................................................................1
Washer, 1/8" Thick.......................................................1
Crowfoot Socket, 3/4" ..................................................1
Torque Wrench, ft. lbs..................................................1
Wire Tie, 10" long ........................................................1
Repair and Service Manual
B
B
Qty.
Page E-15