Rack And Pinion Unit Disassembly - E-Z-GO TXT 48V Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
Rack and Pinion Unit Disassembly and
Inspection
Tool List
Vice ............................................................................. 1
Socket, 3/8", 3/8" drive ................................................ 1
Ratchet, 3/8" drive....................................................... 1
Wrench, 11/16" ............................................................ 1
Wrench, 3/4"................................................................ 1
Wire cutter ................................................................... 1
Retaining ring pliers..................................................... 1
Shop towel................................................................ AR
CITGO Lithoplex MP No. 2 grease........................... AR
Wire tie, 8" long ........................................................... 1
Wire tie, 10" long ......................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
NOTICE
The rack and pinion gears are not serviceable items. If they
are found to be damaged or excessively worn, a new rack and
pinion unit must be installed.
Secure rack and pinion unit in vice by the mounting
ears only. The rack and pinion unit is made of alumi-
num and can be damaged if held otherwise.
Remove rack and pinion unit from vehicle. "Rack and
Pinion Unit Replacement" on Page F-14 Anchor in vice
by clamping on the mounting ears of the unit.
Disassemble rack and pinion unit (1) by first removing
screw (13) and tensioner (2) to relieve pressure on rack
(3) and pinion (4) (Ref. Fig. 17 on Page F-13). Loosen
jam nut (5) and remove rack ball joint (6) from rack
extension (7). Cut wire ties (8, 14) securing bellows (9)
and slide bellows off rack extension. Pull rack (3) from
unit (1). Remove pinion seal (10). "Pinion Seal Replace-
ment" on Page F-11 Remove internal retaining ring (11)
from rack and pinion unit and pull out pinion (4) and ball
bearing (12) as an assembly.
Clean rack, pinion and housing. Inspect gear teeth,
bearing surfaces and grease seal surfaces of rack and
pinion for excessive wear or damage. If any is found, the
rack and pinion unit must be replaced as an assembly.
"Rack and Pinion Unit Replacement" on Page F-14.
If rack and pinion pass inspection, clean them, tensioner
and housing thoroughly and lubricate for assembly. Use
grease specified in tool list.
FRONT SUSPENSION AND STEERING
Qty. Required
6
Assemble rack and pinion unit by first installing pinion in
reverse order of removal making sure to lubricate pinion
seal lip prior to installing seal. "Pinion Seal Replace-
ment" on Page F-11 Insert rack into rack and pinion unit.
Turn pinion clockwise to help pull rack in if necessary.
Install bellows and secure to rack extension with wire tie
(8). Do not secure large end of bellows to rack and pin-
ion unit until instructed to do so after setting proper rack
extension-to-rack and pinion unit clearance. Install ten-
sioner and tighten bolts (13) to 100 - 120 in. lbs. (115 -
138 kg cm) torque. Thread jam nut and rack ball joint to
original location on rack extension and set jam nut hand
tight.
Install rack and pinion unit on vehicle. "Rack and Pinion
Unit Replacement" on Page F-14.
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 steer-
ing 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 F-14.
Repair and Service Manual
5
9
8
7
14
Fig. 17 Rack and Pinion Unit Disassembly
13
2
3
1
11
10
4
12
Page F-13