Tracker Off-Road 800SX Service Manual page 28

INSPECTING RACK AND PINION
1. Inspect the tie rod ends for damaged threads, torn
boots, or excessive wear.
2. Inspect the tie rods for bends or deformation.
3. Inspect the rack and pinion-to-tie rod boots for tears
or deterioration.
MOD322
4. Check boot clamps for security.
5. Check that the steering assembly operates smoothly
with no binding from full-left to full-right position.
6. Inspect for grease seepage from the steering assem-
bly.
NOTE: The steering assembly (rack and pinion) is

only serviceable as an assembly; however, the tie rods
and boots are replaceable.
INSTALLING RACK AND PINION
1. From the passenger side, install the rack and pinion;
then line up marks on the U-joint with the rack and
pinion; then connect the U-joint to the rack and pin-
ion. Install the bolt and new lock nut securing the U-
joint to the rack and pinion. Tighten to 45 ft-lb (61.2
N-m).
2. Install the four cap screws and new lock nuts secur-
ing the rack and pinion bracket to the frame. Tighten
the upper cap screws to 45 ft-lb (61.2 N-m) and the
lower cap screws to 16 ft-lb (21.8 N-m).
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26
MOD320
MOD321
3. Place the outer tie rod ends into the knuckles and
secure with the castle nuts (B) (coated with red Loc-
tite #271). Tighten to 32 ft-lb (43.5 N-m); then install
new cotter pins (A) and spread the cotter pins.
NOTE: If the slots in the castle nut (B) are not

aligned with the hole in the outer tie rod end, tighten
until the cotter pin can be installed.
MOD316
MOD315