Club Car Gasoline Service Manual page 95

2. Install the washer (33), a new tie rod lock washer (34), and a new ball joint (10). Tighten using two
wrenches, one on the ball joint and one on the rack (9). Tighten the ball joint to 50-55 ft.lbs. (68/75 N-m)
(Figure 8-7, Page 8-8). See NOTE below.
CAUTION
• MAKE SURE THAT THE TIE ROD LOCK WASHER (2) (FIGURE 8-7, PAGE 8-8) ALIGNS WITH
THE SLOTS IN THE RACK.
3. Bend the edges of the tie rod lock washer (34) up against the ball joint (Figure 8-7, Page 8-8).
4. Apply a liberal amount of grease to the teeth of the rack (9), then slide the rack through the bushing (7)
and housing (25). Install the washer (3), tie rod lock washer (2), and stopper bolt (1) to the end of the
rack. Using two wrenches, one on the rack and one on the stopper bolt, tighten the stopper bolt to 50-
55 ft.lbs. (68/75 N-m) (Figure 8-7).
5. Bend the edges of the lock washer (2) up against the stopper bolt (Figure 8-7, Page 8-8).
CAUTION
• IN STEP SIX, DO NOT PRESS AGAINST OUTER RACE OF THE BEARING.
6. If the bearing (28) was removed, press on a new bearing, exerting all pressure on the inner race
(grease the bearing before installing it). Then install the external snap ring (36) (Figure 8-7, Page 8-8).
7. If the bearing (26) is damaged, the bearing and housing (25) must be replaced as an assembly (Figure
8-7, Page 8-8).
8. Install the pinion (27) and bearing (28) assembly into the housing (25). Make sure the rack gear teeth
will mesh with the gear teeth on the pinion. The rack may need to be rotated slightly while lightly tap-
ping on the pinion-bearing assembly with a rubber mallet (See CAUTION below).
CAUTION
• DO NOT FORCE THE PINION-BEARING ASSEMBLY INTO THE HOUSING. GEAR TEETH OR
THE SMALL NEEDLE BEARINGS COULD BE DAMAGED.
FIGURE 8-12
BEND
WASHER
EDGES
DOWN
STOPPER
BOLT
FLAT EDGE
RACK
FLAT EDGE
FIGURE 8-13
8
E
G
Page 8-11