Rack And Pinion Assembly - Club Car TURF 272 2005 Maintenance Service Manual

STEERING AND FRONT SUSPENSION

RACK AND PINION ASSEMBLY

1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing
(17) and housing (1) (Figure 7-19, Page 7-10).
CAUT ION
• In step 2, do not press against the outer race of the bearing.
2. If the pinion bearing (15) was removed, grease a new bearing before installation. Press new bearing onto
pinion shaft, exerting all pressure on the inner race. Then install the c-type stop ring (16). See previous
CAUTION.
3. Install pinion (3) and bearing (15) assembly into the housing (1). Make sure the rack gear teeth will mesh
with the gear teeth on the pinion. The rack may need to be rotated slightly while lightly tapping on the pin-
ion-bearing assembly with a rubber mallet. See following CAUTION.
CAUT ION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small
bearing could be damaged.
4. Install the snap ring (4).
5. Use a socket to apply pressure evenly and press in a new dust seal (Figure 7-20, Page 7-11).
6. Apply a small amount of grease to the rack guide (5) where it comes into contact with the rack (2)
(Figure 7-19, Page 7-10).
7. Install the rack end ball joints (9) onto the rack (2) by securing the rack in a vise using wood blocks
between the rack and the jaws of the vise to protect the rack from damage. Tighten the ball joints to 60
ft-lb (81 N·m).
8. Tap a flange into the notch on the rack (Figure 7-23, Page 7-12).
9. Place a few drops of Loctite
10. Install the rack guide (5), pressure spring (6) and screw (7). The screw should be threaded-in until it bot-
toms out and then backed out 1/4 turn (Figure 7-21, Page 7-11).
Figure 7-20 Press In Dust Seal
2005 Turf/Carryall 272/472 and XRT 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
®
222 to the threads of the screw (7).
RUBBER MALET
15/16-INCH DEEP WELL
SOCKET
DUST SEAL
IN PLACE
7
8
Figure 7-21 Rack and Pinion Adjustment
7
Rack and Pinion
Page 7-11