Cushman HAULER 800X Technician's Repair And Service Manual page 59

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
and removing the ball joint (21) from the rack
(Ref Fig. 7).
Rack Ball Joint Installation
Clean threads. Apply primer (LOCTITE LOCQUIC
PRIMER T, #7471) and thread locking adhesive (LOC-
TITE RED #271) to rack ball end before attachment to
steering rack. The ball joint (21) and jam nut (36) should
be threaded into the rack until the dimension between
the end of the rack and the center of the ball joint stud is
14 27/32" (37.7 cm). Tighten the jam nut (36) to the
specified torque (Ref Fig. 8).
ITEM TORQUE SPECIFICATION
36 25 - 30 ft. lbs (35 - 40 Nm)
See 'Rack Replacement' above for installation of rack
into steering housing
14 27/32"
(377 mm)
Fig. 8 Rack Ball Joint Installation
Steering Pinion and Bearing Replacement
Tool List
Retaining ring pliers..................................................... 1
To remove the steering pinion bearing, refer to 'Steering
Shaft Replacement' above. Once the steering shaft is
removed, remove the pinion retainer (37) from the steer-
ing housing and pull the pinion (38) and bearing (39) as
an assembly from the housing (Ref Fig. 7).
The steering pinion bearing (39) can be removed from
the pinion gear (38) by removing the external snap ring
(40) and pressing the bearing from the pinion shaft.
The steering pinion gear bushing (41) is designed to last
the life of the vehicle. If in the unlikely event that it
should require replacement, a competent machine shop
must remove the bushing without damage to the bore. A
new pinion bushing can then be inserted. The rack and
steering pinion must be replaced as a set.
FRONT SUSPENSION AND STEERING
21
36
38 - 40 ft. lbs
(51 - 54 Nm)
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Repair and Service Manual
MAINTENANCE
Good routine maintenance of the front suspension and
steering consists of routine lubrication (See Lubrication
Chart and the Periodic Service Schedule in Section 'A').
Be sure to use only the recommended lubricants. Main-
tain the correct adjustment of the front bearings and
repack them in accordance with the periodic service
schedule or if a bearing replacement is required. Rou-
tine examination of the tires will provide indications that
an alignment is required.
Lubrication
Tool List
Grease gun ..................................................................1
Grease the rack tensioner (26) at fitting (29), the idler
bushing (15) at (42), rack ball joint (21) at (43), and spin-
dle (11) (Ref Fig. 1) per Periodic Service Schedule.
Do not use more than three (3) pumps of grease in each
grease fitting at any one time. Excess grease may cause
grease seals to fail or grease migration into areas that
could damage components.
Wheel Bearing Inspection/Packing
Tool List
Floor jack .....................................................................1
Jack stands..................................................................2
Wheel chocks ..............................................................4
Wrench, 1 1/2" .............................................................1
Needle nose pliers .......................................................1
Non-ferrous punch .......................................................1
Ball peen hammer........................................................1
Ratchet ........................................................................1
Socket, 3/4" .................................................................1
Extension, 6"................................................................1
Grease gun ..................................................................1
Bearing packer.............................................................1
Lift the front of the vehicle and support on jack stands as
per Section 'B'. Rotate the front wheel and feel for any
roughness. Grasp the outside of the tire and rock it. If
any movement is detected the wheel bearing may
require replacement/adjustment. If the wheel bearing is
satisfactory, a worn king pin/bearing is indicated. See
'King Pin Bushing Replacement'.
Remove the wheel.
B
B
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