Cushman HAULER 800X Technician's Repair And Service Manual page 76

FRONT SUSPENSION AND AXLE MOUNTED STEERING
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
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 lock nut (2) to 36 ft. lbs. (50 Nm). 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 - 13.
Rack and Pinion Unit Disassembly and
Inspection
Tool List
Vice.............................................................................. 1
Socket, 3/8" ................................................................. 1
Ratchet ........................................................................ 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. 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
(3) and pinion (4) (Ref Fig. 30). Loosen jam nut (5) and
remove rack ball joint (6) from rack extension (7). Cut
Page E-24
NOTICE
NOTICE
Repair and Service Manual
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 Replacement" on page E -
22 Remove internal retaining ring (11) from rack and pin-
ion unit and pull out pinion (4) and ball bearing (12) as
an assembly.
5
6
8
Qty.
Fig. 30 Rack and Pinion Unit Disassembly
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 - 25
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 - 22 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. (11 - 14 Nm) 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 - 25.
9
13
7
3
14
11
10
2
1
4
12