Tie Rod Inspection/Replacement; Rack Ball Joint Installation; Tie Rod Replacement - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
To install new rack ball joint close to its correct position,
measure amount of threads exposed from jam nut (Ref
Fig. 13).
Measure exposed thread length
and use length to position new
ball joint at same location
Fig. 13 Rack Ball Joint Installation
Loosen jam nut (4) and remove rack ball joint from rack
extension (5).
Using measurement made earlier, thread jam nut and
new rack ball joint to previous location on rack extension
and set jam nut hand tight.
Attach rack ball joint to spindle arm. Tighten castellated
nut (3) to 36 ft. lbs. (50 Nm) torque and continue to
tighten as needed to insert new cotter pin (2). Maximum
torque is 50 ft. lbs. (70 Nm).
After replacing or servicing steering components, always
verify that an 1/8" gap exists between large hex of rack
extension and rack and pinion unit when steering is
turned fully to the right forcing passenger spindle arm
against front axle (Ref Fig. 21).
Check for proper rack extension-to-rack and pinion unit
clearance before tightening jam nut (4) to 35 - 45 ft. lbs.
(47 - 61 Nm) torque. "Checking/Adjusting Rack Exten-
sion-to-Rack and Pinion Unit Clearance" on page E - 15.
Install passenger side front wheel 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.
FRONT SUSPENSION AND STEERING

Tie Rod Inspection/Replacement

Tool List
Tape Measure ..............................................................1
Wrench, 3/4" ................................................................1
Wrench, 9/16" ..............................................................1
Needle Nose Pliers ......................................................1
Wrench, 11/16" ............................................................1
Ball Joint Separator .....................................................1
Plastic Faced Hammer ................................................1
Socket, 11/16"..............................................................1
Torque Wrench, ft. lbs..................................................1
Crowfoot Socket, 3/4" ..................................................1
Grasp the tie rod (8) at ball joints (6) and check for any
vertical motion which would indicate a worn condition
and require replacement (Ref Fig. 12).
To remove tie rod, loosen wheels and lift and support
front of vehicle per SAFETY section.
Remove front wheel.
To install new tie rod ball joint close to its correct posi-
tion, measure the exposed thread length from jam nut
(Ref Fig. 14).
Loosen jam nut (7) at threaded tube (8).To hold
threaded tube while loosening jam nut, use a wrench on
the center, flat section of tube (Ref Fig. 12).
The tie rod has different threads on each end. The end with
the flat area on the threaded tube has left hand threads (clock-
wise to loosen) while the end without the flat has conventional
right hand threads (counter-clockwise to loosen) (Ref Fig. 14).
Remove lock nut (10) until tie rod ball joint (6) threads
are protected. Using a ball joint separator as a lever,
apply pressure to ball joint and tap nut with plastic faced
Repair and Service Manual
Flat section towards end identifies
end with left hand threads
Measure threads showing for length to
position new ball joint at same location
Fig. 14 Tie Rod Replacement
NOTICE
B
B
Qty.
Page E-11