Tracker Off-Road 500S Service Manual page 24

6. With the spacers in place, secure the lift support to
the steering column using the cap screw and nut.
Tighten securely.
PK115
7. Install both upper and lower steering column covers
and secure using the cap screws and reinstallable
inserts. Insert the rubber plugs into the covers.
8. Install the steering wheel (see Steering Wheel in this
section).
REMOVING RACK AND PINION
1. Remove the steering shaft; then remove the front
wheels.
2. Remove the cotter pins and castle nuts securing the
tie rod ends to the knuckle. Account for the washers;
then remove the tie rod ends from the knuckles.
PK121
3. Remove the cap screws securing the steering rack
assembly to the frame and remove from the left side.
PK122A
22
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.
PR785
4. Verify the cable ties for each boot are secure and in
good condition. Replace if necessary.
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
not repairable and must be replaced as an assembly;
however, the tie rods and boots are replaceable.
INSTALLING RACK AND PINION
1. From the left side, install the steering assembly (rack
and pinion) to the frame assembly and secure with
two cap screws. Tighten to 34 ft-lb (46.2 N-m).
2. Place the tie rod ends into the knuckles. Install the
washers; then secure with the castle nuts (coated
with red Loctite #271). Tighten to 25 ft-lb (34 N-m);
then install new cotter pins.
NOTE: If the slots in the castle nut are not aligned

with the hole in the tie rod end, tighten until the cotter
pin can be installed.
3. Install the steering shaft (see INSTALLING STEER-
ING SHAFT ASSEMBLY).
4. Install the wheels and using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre-
ments to a final torque of 45 ft-lb (61.2 N-m) (steel
wheel), 60 ft-lb (81.6 N-m) (aluminum wheel w/black
nuts), or 80 ft-lb (108.8 N-m) (aluminum wheel w/
chrome nuts).
REMOVING TIE RODS
1. Remove the steering rack assembly (see REMOV-
ING RACK AND PINION in this section).
2. Support the steering rack assembly in a suitable
holding fixture or bench vise; then cut the securing
band and slide the boot toward the outer tie rod end.
3. Using a punch or chisel, bend the lock washer away
from the flats on the tie rod joint.