Rack And Pinion; Rack And Pinion Removal; Rack And Pinion Disassembly - Club Car DS 2004 Service Manual

7
STEERING AND FRONT SUSPENSION

RACK AND PINION

See General Warning, Section 1, Page 1-1.

RACK AND PINION REMOVAL

1. Remove the front body as instructed in Section 4 – Body and Trim.
2. Remove the cotter pin (22) and ball joint retaining nut (25) (Figure 7-9, Page 7-9).
3. Using a ball joint removal tool, remove the ball joint (23) (Figure 7-9, Page 7-9) from the spindle assem-
bly. See Figure 7-8, Page 7-7.
4. Remove the bolts (30), washers (31), and lock nuts (32) from the steering rack assembly mounting
bracket (Figure 7-9, Page 7-9).
5. Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and
universal joint from the vehicle (Figure 7-3, Page 7-3).

RACK AND PINION DISASSEMBLY

CAUTION
• The ball joint (23) (Figure 7-9, Page 7-9) has left-hand threads.
1. Remove ball joint (23) and inspect it for excessive wear (Figure 7-9, Page 7-9).
2. Remove the drag link (28) (Figure 7-9, Page 7-9).
3. Remove both bellows clamps (2) (plastic wire ties).
4. Remove the hex nut (29) and slide off the dust seal bellows (1).
5. Remove the retaining ring (21), then slide off dust seal bellows (20).
6. Remove the rack screw lock nut (15), rack guide screw (16), rack guide pressure spring (14), and the rack
guide (13).
7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off the
universal joint.
8. If necessary, remove the dust seal (12). See following NOTE.
NOTE: If the dust seal (12) is removed, replace with a new one (Figure 7-9, Page 7-9).
9. Using snap ring pliers, remove the internal snap ring (11) (Figure 7-9, Page 7-9).
10. Install the universal joint onto the pinion and place a large open end wrench under the universal joint
(Figure 7-10, Page 7-10). Use the wrench as a lever to pull the pinion from the housing.
Page 7-8 2004 DS Golf Car Maintenance and Service Manual
Rack and Pinion