Club Car Gasoline Service Manual page 93

5. Loosen the bolt on the upper universal joint, then remove the rack assembly and universal joint from
the vehicle (Figure 8-7).
RACK AND PINION DISASSEMBLY (SEE NOTE BELOW)
NOTE
• DURING THE 1996 MODEL YEAR, CLUB CAR INCORPORATED A NEW RACK AND PINION
ASSEMBLY. FOR DS GASOLINE VEHICLES PRIOR TO SERIAL NO. AG9633-517735, AND FOR
DS ELECTRIC VEHICLES PRIOR TO SERIAL NO. A9640-533437, FOLLOW THE INSTRUCTIONS
BELOW. FOR DS VEHICLES WITH THESE OR HIGHER SERIAL NUMBERS, SEE PAGE 8-13.
WARNING
• THE RACK AND PINION MUST BE SERVICED EXACTLY AS INSTRUCTED IN THIS MANUAL.
FAILURE TO FOLLOW PROPER PROCEDURES COULD CAUSE A LOSS OF STEERING WHICH
COULD RESULT IN PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH!
CAUTION
• THE BALL JOINT (13) (FIGURE 8-7) HAS LEFT HAND THREADS.
1. Remove the ball joint (13) (Figure 8-7) and inspect it for excessive wear (See Figure 8-6, Page 8-7).
2. Remove the drag link (17) (Figure 8-7).
3. Remove both bellows clamps (4) (Figure 8-7).
4. Remove the hex nut (11) and slide off the dust seal bellows (35) (Figure 8-7).
5. Remove the snap ring (31) and washer (32), then slide off dust seal bellows (5) (Figure 8-7).
6. Remove the rack guide screw (21), rack screw lock nut (22), rack guide pressure spring (23), and the
rack guide (24) (Figure 8-7).
7. Remove the universal joint assembly from the pinion (27) by fully removing the bolt and then sliding off
the universal joint.
8. Using an awl or other suitable tool, remove the dust seal (30) (Figure 8-7, Page 8-8) (See Figure 8-8,
Page 8-10).
NOTE
• IF THE DUST SEAL (30) IS REMOVED, REPLACE IT WITH A NEW ONE.
9. Using snap ring pliers, remove the internal snap ring (29) (Figure 8-7) (See Figure 8-9, Page 8-10).
10. Install the universal joint onto the pinion (27) (Figure 8-7) and place a large open end wrench under the
universal joint. Use the wrench as a lever to pull the pinion from the housing (Figure 8-10, Page 8-10).
11. If the ball bearing (28) (Figure 8-7) has been damaged, remove the external snap ring (36) (Figure 8-
7) and press the bearing off (See Figure 8-11, Page 8-10).
12. Bend the edges of the washer (2) down and remove the rack (9) from the housing (25) (Figure 8-7)
(See Figure 8-12, Page 8-11).
13. Using two wrenches, one wrench on the rack (9) and one on the stopper bolt (1) (Figure 8-7), remove
the stopper bolt from the rack (See Figure 8-13, Page 8-11).
14. Remove the tie rod lock washer (2) and the washer (3), then slide the rack out (Figure 8-7).
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