Cushman HAULER 800X Technician's Repair And Service Manual page 60

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
Remove the dust cap (14), cotter pin (15) castellated nut
and washer (16), outer roller bearing (18) and hub
assembly (17) from the spindle (Ref Fig. 9). Remove the
inner bearing seal (20), inner roller bearing (18) and
bearing races (19) by tapping lightly around the bearing
race through the hub using a soft non ferrous punch. Tap
the punch in a circular pattern to avoid damaging the
bore of the hub. Clean all bearings, seal, hub and dust
cap in solvent and dry thoroughly. Inspect for signs of
damage. Pitting or a blue coloration of the rollers will
require replacement of the bearing. If the roller portion of
the bearing is to be replaced, the race must also be
replaced. Install new bearing only after packing with
grease.
Front of Vehicle
15
18
19
16
14
Fig. 9 Wheel Bearing Replacement
The front wheel bearings are tapered roller type and
must be packed with grease at installation, or any time
that the bearing is removed for inspection. It is recom-
mended that a bearing packer attached to a grease gun
be used; however, manual packing is acceptable if done
correctly. To pack a bearing manually requires that a dab
of grease be placed in the palm of the hand and the
bearing be dipped in the grease. Force the grease up
through and around all of the rollers until the entire bear-
ing is coated in grease. Fill the area between the rollers
with grease and apply a light coating to the bearing race.
Install bearing in race.
Seal Installation
Clean the hub seal surface to remove grease and press
the inner bearing seal into place with the flange side of
the seal facing into the bore. Tap gently into place with a
seal installation tool until it is flush with the outside of the
hub assembly. Lubricate the seal surface with a light oil.
(Ref Fig. 10)
Page E-8
18
20
19
17
Repair and Service Manual
A - Install this side of seal
into housing
B - Lubricate seal surface
Fig. 10 Seal Installation
Bearing Adjustment
Assemble hub with bearings on spindle. Reinstall wheel
on hub. Rotate the wheel while tightening the castellated
nut (1). (Ref Fig. 11) Tighten the castellated nut until
slight resistance to rotation is noticed.
3
1
4
Fig. 11 Front Spindle and Bearing
Rotate the wheel 2 - 3 more turns to displace excess
grease. If required, tighten castellated nut again until
slight resistance is felt. If the cotter pin hole in the spin-
dle (2) aligns with a slot in the castellated nut (1), insert
a new cotter pin (3). If the hole does not align, the cas-
tellated nut must be loosened to align with the closest
available slot in the nut.
Check for smooth and free rotation of the wheel and an
absence of play when the wheel is grasped by the out-
side of the tire. Bend the cotter pin (3) against the flats of
the castellated nut (1) and cut off any excess.
Replace the dust cap (4).
King Pin Bushing Replacement
Tool List
Floor jack .....................................................................1
Jack stands ..................................................................2
Wheel chocks ..............................................................4
Pliers ............................................................................1
Box end wrench, 15/16"...............................................1
B
A
2
Qty.