Rack And Pinion Installation - Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

STEERING AND FRONT SUSPENSION
CAUTION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing
could be damaged.
4. Install the large snap ring (2).
5. Use a socket (1) to apply pressure evenly and press in a new dust seal (2) (Figure 7-10, Page 7-10).
6. Apply a small amount of grease to the rack guide (16) where it comes into contact with the rack (18) (Figure 7-5,
Page 7-7).
7. Install the ball joints (8) onto the rack (18) 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 7-11, Page 7-10).
9. Place a few drops of Loctite 222 to the threads of the rack screw nut (14) (Figure 7-5, Page 7-7).
10. Install the rack guide (16), pressure spring (15) and rack guide screw (13). The screw should be threaded-in
until it bottoms out and then backed out 1/4 turn (Figure 7-5, Page 7-7).
11. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the splines of the pinion shaft.
12. Install lower end of the universal joint (2) onto pinion shaft and secure with bolt (1) (Figure 7-13, Page 7-10).
Tighten bolt (1) to 15 ft-lb (20.3 N·m).
13. To adjust rotational resistance (preload), insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column
(upper) end of the universal joint (2) and tighten the bolt (1) to 15 ft-lb (20.3 N·m) (Figure 7-13, Page 7-10).
14. Use a torque wrench connected to the 3/8-inch deep-well socket to measure the resistance of the rack and
pinion. Rotational resistance should measure 7 to 15 in-lb (0.8 to 1.7 N·m).
15. If measured resistance is not 7 to 15 in-lb (.8 to 1.7 N·m), adjust the screw (13) until correct setting is achieved.
Tighten the nut (14) to 28 ft-lb (38 N·m) (Figure 7-12, Page 7-10).
NOTE: When tightening the nut (14), make sure the screw (13) does not change adjustment (Figure 7-12, Page 7-10).
16. Remove the 3/8-inch, 1/4-drive, deep-well socket from the steering column end of the universal joint (2).
17. Install the two dust seal bellows (9) (Figure 7-5, Page 7-7).
18. Install new bellows clamps (wire ties) (10 and 21).
19. Install the tie rod ends (12) to each end of rack (18). Tighten the tie rod end jam nuts (11) to 26 ft-lb (35 N·m)
(Figure 7-5, Page 7-7).

RACK AND PINION INSTALLATION

1. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the end of the steering column shaft.
2. Simultaneously slide the universal joint over the square end of the steering column shaft and position the
assembly over the mounting holes in the chassis.
3. Install three screws to secure the assembly to the chassis. Tighten screws to 22 ft-lb (30 N·m).
4. Install the upper universal joint bolt (7) and tighten to 18.4 ft-lb (25 N·m) (Figure 7-4, Page 7-5).
5. Install the tie rod ends (3) into the left- and right-hand spindle tabs (4), and then install the retaining nuts (2)
(Figure 7-4, Page 7-5). See following WARNING.
WARNING
• Do not operate vehicle until toe-in is adjusted and ball joints are secured.
6. Adjust the toe-in. See Toe-in Adjustment on page 7-12.
2009-2011 Electric Precedent Maintenance and Service Manual
7
Rack and Pinion
Page 7-9