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7
STEERING AND FRONT SUSPENSION
Steering Column Assembly, Continued:
3. Install the wedge (16), spring (15), washer (14), and snap ring (13) onto the bottom end of the steering
shaft (19) (Figure 7-5, Page 7-5).
4. Insert the shaft (19) from the bottom of the steering tube (20) (Figure 7-3, Page 7-3).
5. Turn the assembly over and place the shaft (19) on a bench. Install the wedge (16) and retaining ring (22)
onto the top of the shaft (Figure 7-6, Page 7-5). Be sure the prongs on the retaining ring face up and
away from the wedge. Use a steering column retaining ring tool (CCI P/N 1014259) to seat the retaining
ring to the proper depth. Support end of tube while pressing. If you do not have the recommended tool,
use the same tube as was used in step 2 to press the retaining ring onto the top of the shaft. The retaining
ring should be pressed onto the shaft until 2 to 2-1/8 inches (5.1-5.4 cm) of the shaft extends from the
top of the bearing seat in the steering tube (Figure 7-6, Page 7-5).
STEERING COLUMN INSTALLATION
1. Install boot (12). Reinstall mount (4 and 5) onto the end of the steering column. Tighten bolts (6) to 20
ft-lb (27 N·m) (Figure 7-3, Page 7-3).
2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound
to both splined ends of the steering shaft.
3. Position the steering column assembly in the vehicle while inserting the steering column shaft into the
upper universal joint (1). The flat portion of the steering shaft spline (19) must be aligned with the bolt hole
in the universal joint (1) before sliding the spline into the universal joint. While holding the steering column
in place, attach it to the frame using bolts (8) washers (7) and nuts (9) (Figure 7-3, Page 7-3). Thread
the nuts onto the bolts but do not tighten them.
4. Reinstall washer (11) and screw (10). Tighten to 20 ft-lb (27 N·m).
5. Install the bolt (2) and lock washer (3) on the upper universal joint and finger-tighten.
6. Tighten the two nuts (9) and bolts (8) to 17 ft-lb (23 N·m).
7. Tighten the bolt (2) on the upper universal joint to 15 ft-lb (20 N·m).
8. Check the other two bolts on the universal joint (1) to ensure that they are properly tightened to 15 ft-lb
(20 N·m) (Figure 7-3, Page 7-3).
9. Reinstall dash pocket and related hardware.
10. Reinstall center dash panel in reverse order of disassembly. Make sure the key switch terminals do not
touch the frame and the center dash panel is properly seated and snapped into place.
11. Install front body and bumper. See Section 4 – Body and Trim.
STEERING ADJUSTMENT
See General Warning, Section 1, Page 1-1.
1. Turn the steering wheel all the way to the right. Note the distance between the passenger-side spindle
stop (2) and passenger-side A-plate (3) (Figure 7-7, Page 7-7). The internal stop on the rack must reach
its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the
passenger-side A-plate (with vehicle wheels turned to the right). If simultaneous contact occurs, steering
is in correct adjustment; Proceed to step 4. If simultaneous contact does not occur, proceed to step 2.
Page 7-6
2004 DS Golf Car Maintenance and Service Manual
Steering Adjustment
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