Cushman HAULER 800X Technician's Repair And Service Manual page 77

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.
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.
Set proper rack extension-to-rack and pinion unit clear-
ance. "Checking/Adjusting Rack Extension-to-Rack and
Pinion Unit Clearance" on page E - 25.
Rack and Pinion Unit Replacement
Tool List
Socket, 13 mm ............................................................ 1
Ratchet ........................................................................ 1
Needle Nose Pliers...................................................... 1
Wrench, 11/16" ............................................................ 1
Ball Joint Separator ..................................................... 1
Plastic Faced Hammer ................................................ 1
Wrench, 5/8"................................................................ 1
Socket, 5/8" ................................................................. 1
Ratchet ....................................................................... 1
Torque Wrench, ft. lbs. ................................................ 1
Socket, 11/16" ............................................................. 1
Torque Wrench, in. lbs................................................. 1
To remove rack and pinion unit (12) (Ref Fig. 25), loosen
front wheels and lift and support front of vehicle per
SAFETY section. Remove front wheels.
Remove bolt (13) and washer (14) securing intermediate
shaft (15) to rack and pinion unit (12).
Remove cotter pin (2) and loosen castellated nut (3)
until rack ball joint (1) threads are protected. 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 passenger side spindle arm. Remove nut from ball
joint and ball joint from spindle arm.
Remove the three lock nuts (18) securing rack and pin-
ion unit to front axle and discard nuts. The rack and pin-
ion unit can now be removed from vehicle. Retain
washers (19), spacers (20) and the two bolts (16) for
assembly.
Replace rack and pinion unit in reverse order of
removal.
Use new lock nuts (18) and tighten them to 35 - 50 ft.
lbs. (50 - 70 Nm) torque.
Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque
and continue to tighten as needed to insert new cotter
pin. Maximum torque is 50 ft. lbs. (70 Nm).
Tighten bolt (13) securing intermediate shaft to pinion to
155 - 215 in. lbs. (18 - 24 Nm) torque.
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
Qty.
turned fully to the right forcing passenger spindle arm
against front axle.
Set proper rack extension-to-rack and pinion unit clear-
ance. "Checking/Adjusting Rack Extension-to-Rack and
Pinion Unit Clearance" on page E - 25.
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.
Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance
Tool List
Wrench, 11/16" ............................................................1
Wrench, 3/4" ................................................................1
Wrench, 1/2" ................................................................1
Wire Cutter...................................................................1
Washer, 1/8" Thick.......................................................1
Crowfoot Socket, 3/4" ..................................................1
Torque Wrench, ft. lbs..................................................1
Wire Tie, 10" long ........................................................1
Check for proper rack extension-to-rack and pinion unit
clearance by first turning steering wheel fully to the right.
The rear spindle arm on the passenger side must rest
against the front axle (Ref Fig. 31). If it does not, all
adjustment is made at the rack ball joint (6) (Ref Fig.
32). Loosen jam nut (5) at rack ball joint and use wrench
to thread shaft of rack extension (7) further into rack ball
Repair and Service Manual
B
B
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Page E-25