Rack And Pinion Assembly - Club Car DS 2004 Service Manual

STEERING AND FRONT SUSPENSION

RACK AND PINION ASSEMBLY

1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-12, Page 7-10). Install the ball joint onto
the rack 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 joint to 60 ft-lb (81 N·m).
2. Bend the edges of the tab washer (4) up against the ball joint (3).
3. Apply a liberal amount of EP grease to the teeth of the rack (17), then slide the rack through the housing
(6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-9, Page 7-9). See
following CAUTION.
CAUTION
• In step 4, do not press against the outer race of the bearing.
4. If the bearing (9) was removed, grease and press on a new bearing, exerting all pressure on the inner
race. (Figure 7-9, Page 7-9)
5. Install the external snap ring (10).
6. If the needle bearing (7) is damaged, the steering box assembly (CCI P/N 101878302) must be replaced.
7. Install pinion (8) and bearing (9) assembly into the housing (6) (Figure 7-9, Page 7-9). 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 pinion-bearing assembly with a rubber mallet. See following CAUTION.
CAUTION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing
could be damaged.
8. Install the internal snap ring (11) (Figure 7-9, Page 7-9).
9. Use a socket to apply pressure evenly, and press in a new dust seal (Figure 7-13, Page 7-11).
Figure 7-13 Press In Dust Seal
10. Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17)
(Figure 7-9, Page 7-9).
11. Place a few drops of Loctite
15/16-INCH
DEEP WELL
SOCKET
DUST SEAL
®
222 on the threads of the screw (16) (Figure 7-9, Page 7-9).
2004 DS Golf Car Maintenance and Service Manual
7
Rack and Pinion
Page 7-11