Rack And Pinion; Rack And Pinion Removal - Pioneer 1200 Maintenance Service Manual

STEERING AND FRONT SUSPENSION
10
14
STEP 1
BEARING
PRESS TOOL
(CCI P/N 1014264)
9
STEP 2
Figure 7-5 Steering Shaft – Bottom End
3. Position the steering column assembly in the vehicle while inserting the steering column shaft into the
upper steering universal joint (1). The flat portion of the steering shaft spline (11) must be aligned with
the bolt hole in the steering universal joint (1) before sliding the spline into place (Figure 7-3, Page 7-2)
4. Install bolt (2) and lock washer (3) on the upper steering joint and finger-tighten (Figure 7-4, Page 7-4).
5. Hold the steering column in place and attach it to the frame using bolts (15), washers (16) and lock nuts
(17) (Figure 7-3, Page 7-2). Tighten the four bolts, in a crisscross pattern to 23 ft-lb (31.2 N·m).
6. Tighten bolt (2) on the upper steering universal joint (1) to 15 ft-lb (20 N·m).
7. Check the other bolts on the lower steering universal joint assembly (1) to ensure that they are properly
tightened to 15 ft-lb (20 N·m) (Figure 7-3, Page 7-2).
8. Install the front body. See Front Body Installation, Section 4, Page 4-4.
9. Install dashboard and dash panel. See Dashboard Installation, Section 4, Page 4-2.
10. Install the steering wheel. See Steering Wheel Installation on page 7-3.
11. Connect the spark plug.
12. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27 N·m). Coat ter-
minals with Battery Terminal Protector Spray (CCI P/N 1014305).

RACK AND PINION

See General Warning, Section 1, Page 1-1.

RACK AND PINION REMOVAL

1. Chock the rear wheels, release the park brake, loosen the front wheel lug nuts and lift the front of the
vehicle with a chain hoist or floor jack. See WARNING "Lift only one end..." in General Warning,
Section 1, Page 1-1.
2. Place jack stands under the outer front frame I-beams and lower onto stands. See Figure 5-2,
Section 5, Page 5-3.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
11
5
6
7
10
8
WEDGE SEATING
INTO THE INNER
RACES OF BEARING
STEP 3
RETAINING TOOL
(CCI P/N 1014259)
STEP 1
14
BEARING
PRESS TOOL
(CCI P/N 1014264)
9
WEDGE SEATING
INTO THE INNER
STEP 2
RACES OF BEARING
Figure 7-6 Steering Shaft – Top End
Rack and Pinion
COLUMN
12
8
11
5.1-5.4 cm
2 in.-2 1/8 in.
10
8
STEP 3
Page 7-5
7