Rack And Pinion Unit Disassembly And Inspection - Ezgo 605586 Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
Spindle installation is the reverse order of disassembly.
The thrust washer (9) is located on top of spindle between
spindle and front axle.
Tighten new lock nut (5) to 56 - 70 ft. lbs. (75 - 95 Nm)
torque. Check that spindle turns freely on king pin tube
after tightening.
Tighten castellated nut (2) to 36 ft. lbs. (50 Nm) torque
and continue to tighten as needed to insert new cotter
pin. Maximum torque is 50 ft. lbs. (70 Nm).
Install front wheels per WHEELS AND TIRES section
and lower vehicle per SAFETY section.
Check front wheel alignment and adjust if necessary.
"Wheel Alignment" on Page E-3)
Rack and Pinion Unit Disassembly and
Inspection
Tool List
Vice ............................................................................. 1
Socket, 3/8", 3/8" drive ................................................ 1
Ratchet, 3/8" drive....................................................... 1
Wrench, 11/16" ............................................................ 1
Wrench, 3/4"................................................................ 1
Wire cutter ................................................................... 1
Retaining ring pliers..................................................... 1
Shop towel................................................................ AR
CITGO Lithoplex MP No. 2 grease........................... AR
Wire tie, 8" long ........................................................... 1
Wire tie, 10" long ......................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
The rack and pinion gears are not serviceable items. If they
are found to be damaged or excessively worn, a new rack and
pinion unit must be installed.
Secure rack and pinion unit in vice by the mounting ears
only. The rack and pinion unit is made of aluminum and
can be damaged if held otherwise.
Remove rack and pinion unit from vehicle. "Rack and
Pinion Unit Replacement" on Page E-14) Anchor in vice
by clamping on the mounting ears of the unit.
Disassemble rack and pinion unit (1) by first removing
screw (13) and tensioner (2) to relieve pressure on rack
FRONT SUSPENSION AND STEERING
(3) and pinion (4) (Ref. Fig. 17 on Page E-13). Loosen
jam nut (5) and remove rack ball joint (6) from rack
extension (7). Cut wire ties (8, 14) securing bellows (9)
and slide bellows off rack extension. Pull rack (3) from
unit (1). Remove pinion seal (10). "Pinion Seal Replace-
ment" on Page E-11) Remove internal retaining ring (11)
from rack and pinion unit and pull out pinion (4) and ball
bearing (12) as an assembly.
6
Qty. Required
Clean rack, pinion and housing. Inspect gear teeth,
bearing surfaces and grease seal surfaces of rack and
pinion for excessive wear or damage. If any is found, the
rack and pinion unit must be replaced as an assembly.
"Rack and Pinion Unit Replacement" on Page E-14)
If rack and pinion pass inspection, clean them, tensioner
and housing thoroughly and lubricate for assembly. Use
grease specified in tool list.
Assemble rack and pinion unit by first installing pinion in
reverse order of removal making sure to lubricate pinion
seal lip prior to installing seal. "Pinion Seal Replace-
ment" on Page E-11) Insert rack into rack and pinion
unit. Turn pinion clockwise to help pull rack in if neces-
sary. Install bellows and secure to rack extension with
wire tie (8). Do not secure large end of bellows to rack
and pinion unit until instructed to do so after setting
proper rack extension-to-rack and pinion unit clearance.
Install tensioner and tighten bolts (13) to 100 - 120 in.
lbs. (115 - 138 kg cm) torque. Thread jam nut and rack
ball joint to original location on rack extension and set
jam nut hand tight.
Install rack and pinion unit on vehicle. "Rack and Pinion
Unit Replacement" on Page E-14)
Repair and Service Manual
5
9
8
7
14
Fig. 17 Rack and Pinion Unit Disassembly
B
B
13
2
3
1
11
10
4
12
Page E-13