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STEERING AND FRONT SUSPENSION
RACK AND PINION ASSEMBLY
1.
Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing (17)
and housing (1) (Figure 7-22, Page 7-12).
CAUTION
• In step 2, do not press against the outer race of the bearing.
2.
If the pinion bearing (15) was removed, grease a new bearing before installation. Press the new bearing onto the
pinion shaft, and exert all pressure on the inner race. Then install the C-type stop ring (16). See preceding
CAUTION.
3.
Install the pinion (3) and bearing (15) assembly into the housing (1). Ensure the gear teeth in the rack (2)
will mesh with the gear teeth on the pinion. It may be necessary to rotate the rack slightly and lightly tap the
pinion-bearing assembly with a rubber mallet. See following CAUTION.
CAUTION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing
could be damaged.
4.
Install the snap ring (4).
5.
Use a socket to apply pressure evenly, and press in a new dust seal (Figure 7-23, Page 7-13).
1. Rubber Mallet 2. 15/16-Inch Deep Well Socket 3. Dust Seal in place.
2058
Figure 7-23 Press In Dust Seal
6.
Apply a small amount of grease to the rack guide (5) where it contacts the rack (2) (Figure 7-22, Page 7-12).
7.
Install the ball joints (9) onto the rack (2). Secure the rack in a vise with wood blocks between the rack and the
jaws of the vise to protect the rack from damage, and tighten the ball joints to 60 ft-lb (81 N·m) (Figure 7-26,
Page 7-14).
8.
Tap a flange into the notch on the rack.
9.
Place a few drops of Loctite 222 on the threads of the screw (7) (Figure 7-24, Page 7-13).
10.
Install the rack guide (5), pressure spring (6), and screw (7). Thread-in the screw until it bottoms out, and
then unscrew it 1/4 turn (Figure 7-22, Page 7-12).
1
2
3
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2014 Carryall 295/XRT 1550 Maintenance and Service Manual
Rack and Pinion
Figure 7-24 Rack and Pinion Adjustment
7
Page 7-13
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Troubleshooting
