Front Axle Replacement; Axle Linkage Rod Replacement - Cushman SHUTTLE 4X Technician's Repair And 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
Installation of shock absorber is reverse of disassembly.
Mounting nuts should be tightened until rubber bushings
(4) expand to diameter of shock absorber washers (5).

Front Axle Replacement

Tool List
Ratchet ........................................................................ 1
Socket, 3/4" ................................................................. 1
Wrench, 9/16" .............................................................. 1
Wrench, 3/4" ................................................................ 1
Plastic Faced Hammer ................................................ 1
Shop Towels ............................................................. AR
Wire .......................................................................... AR
Wrench, 5/8" ................................................................ 1
Wrench, 11/16" ............................................................ 1
Socket, 9/16" ............................................................... 1
Socket, 5/8" ................................................................. 1
Torque Wrench, ft. lbs.................................................. 1
Loosen front wheels. Lift and support front of vehicle per
SAFETY section and remove front wheels.
Remove hardware (1, 4, 5) securing shock absorbers (2)
to front axle (3)(Ref Fig. 6).
On the driver side, remove lock nut (6) and washer (8)
from bolt (7) and discard nut. Pull bolt (7) and washer (9)
from spindle (10) and separate spindle from axle.
Remove thrust washer (11) and king pin tube (12) from
spindle, wrap towel around spindle and let spindle rest
on ground.
Repeat at passenger side letting rack ball joint (29) rest
on front spring to support spindle.
To prevent possible injury from falling steering
components, secure rack and pinion unit (16)
to front springs with wire. This will prevent the
intermediate shaft connecting the rack and pin-
ion unit to the steering column from pulling
apart due to the weight of the steering system.
The intermediate shaft is assembled with the
universal joints set 90° out of phase with each
other.
Remove hardware (13 - 15) securing rack and pinion
unit (16) to front axle and discard lock nuts (15). Move
rack and pinion unit back to rest on top of front springs
(17). Secure rack and pinion unit to spring with wire to
prevent pulling apart intermediate shaft.
Page E-6
Remove the three 1 3/4" long bolts (18), two 1 1/2" long
bolts (28), spring plate (24) and five lock nuts (19) secur-
ing axle to springs and discard lock nuts. At the 3 1/2"
long bolt (20) securing front of left spring, note location
of washer (22) and remove it from end of bolt. Remove
Qty. nut (21), 3 1/2" long bolt (20), spring plate (24) and
spacer (23) and retain them for assembly at their original
locations.
To prevent stress and possible damage to the rack and
pinion unit, the axle must first be mounted to the springs
with the hardware (20 - 23) installed in its original location
(Ref Fig. 6).
To prevent damage to bellows (16), the two 1 1/2" long
bolts (28) must be installed in their original location.
Front axle installation is the reverse order of disassem-
bly using new lock nuts (15, 19). All hardware (18 - 24,
28) must be installed in its original location (Ref Fig. 6).
Tighten leaf spring and rack and pinion unit hardware
(13 - 15,18 - 21, 28) to 35 - 50 ft. lbs. (50 - 70 Nm)
torque.
Install thrust washers (11), king pin tubes (12), spindles,
washers (9) and bolts (7). Tighten new lock nuts (6) to
56 - 70 ft. lbs. (75 - 95 Nm) torque. Check that spindle
turns freely on king pin tube after tightening.
Tighten shock absorber mounting hardware until rubber
bushings expand to diameter of shock absorber washer.
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.

Axle Linkage Rod Replacement

Raise the front of the vehicle (See Lifting Vehicle).
Remove old axle linkage rod by removing each ball joint
nut (Ref Fig. 7). Check axle alignment (Ref Fig. 8).
Adjust length of new axle linkage rod until it will pass
through and seat in the hole in the front axle assembly
and the rear spring plate without resistance. Tighten the
ball joint nuts to 20 - 25 ft. lbs. (27 - 33 Nm) torque and
rod jam nut to 20 - 25 ft. lbs. (27 - 33 Nm) torque. Lower
the vehicle.
Repair and Service Manual