Cushman HAULER 800X Technician's Repair And Service Manual page 58

FRONT SUSPENSION AND STEERING
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
ITEM TORQUE SPECIFICATION
19 35 - 50 ft. lbs (50 - 70 Nm)
16 35 ft. lbs (50 Nm)
Idler Arm Replacement
Tool List
Needle nose pliers....................................................... 1
Wrench, 11/16" ............................................................ 1
Wrench, 1 1/4" ............................................................. 1
To remove the idler arm (18) from the steering housing
assembly (13), remove the steering housing assembly
from the vehicle (as described above) (Ref Fig. 7).
Remove the cotter pin and nut (20) attaching the steer-
ing rack ball joint (21) to the upper idler arm, remove the
lock nut (22) and the two washers (23, 24) from the idler
and remove the idler arm from the steering housing.
Replace idler arm in reverse order of removal.
Tighten nut (22) to the specified torque. Insert a new cot-
ter pin (25).
Tighten nut (20) to the minimum specified torque, if a
cotter pin (25) can not be inserted then continue to
tighten until a slot in the nut (20) aligns with the hole and
a cotter pin is installed, DO NOT tighten past the maxi-
mum specified torque.
Lubricate through grease fitting (42).
ITEM TORQUE SPECIFICATION
22 70 - 80 ft. lbs (95 - 110 Nm)
20 35 - 50 ft. lbs (50 - 70 Nm)
Rack Tensioner Replacement
Tool List
Wrench, 9/16" .............................................................. 1
In general, there is no need to remove the rack tensioner
(26) unless the rack bellows (27) and or the rack cover
(28) have been torn or damaged and there is reason to
believe that water or dirt has entered the housing. (Ref
Fig. 7) The tensioner can be greased through a right
angle grease fitting (29) located on the steering housing
directly behind the front shield. The tensioner does need
to be removed in order to replace the rack (30).
Page E-6
To remove the tensioner, remove the bolts (31), the
cover plate (32) and gasket (33) that secures the rack
tensioner in the steering housing. Remove the spring
(34) and tensioner.
Replace rack tensioner in the reverse order of removal,
replacing gasket (33) with a new one.
Tighten bolts (31) to the specified torque.
Lubricate through grease fitting (29).
Qty.
ITEM
31
Rack Replacement
Tool List
Wrench, 9/16" ..............................................................1
Needle nose pliers .......................................................1
Wrench 11/16"..............................................................1
Ball joint separator .......................................................1
Plastic faced hammer ..................................................1
Straight blade screwdriver ...........................................1
The rack can be removed by loosening the tensioner
bolts (31), removing cotter pin and backing off nut (20)
on rack ball joint (21) until end threads of ball joint are
protected (Ref Fig. 7). Using a ball joint separator as a
lever, apply pressure to ball joint and tap nut with plastic
faced hammer to release ball joint from idler arm.
Remove nut from ball joint and ball joint from idler arm.
Remove the large clamp (35) that secures rack bellows
(27) to the steering housing. The rack and the bellows
may now be pulled from housing.
To test for straightness, lay smooth side of rack on the
edge of a metal straight edge in good condition. If a
.015" (.381 mm) feeler gauge passes between the rack
and the straight edge, the rack is excessively bent and
must be replaced. The rack and steering pinion must
be replaced as a set.
Qty.
Rack replacement is the reverse order of removal. Pull
rack into steering assembly by turning steering wheel.
Rack Ball Joint Removal
For replacement of the rack ball joint, the rack must be
removed from the steering assembly in order to properly
adjust the rack/ball joint length. (See above for rack
removal). The rack end ball joint (21) can be removed
from the steering rack (30); once the rack is removed
from the steering housing by loosening the jam nut (36)
Repair and Service Manual
TORQUE SPECIFICATION
18 - 22 ft. lbs (25 - 30 Nm)
Qty.