Club Car Gasoline Service Manual page 99

10. Install the universal joint onto the pinion and place a large open end wrench under the universal joint
(Figure 8-10, Page 8-10). Use the wrench as a lever to pull the pinion from the housing.
11. If the ball bearing (9) has been damaged, remove the external snap ring (10) (Figure 8-17) and press
the bearing off (See Figure 8-11, Page 8-10).
12. Remove the retaining ring (19) and stop washer (18), then remove the rack (17) from the housing (6)
(Figure 8-17).
13. If the inner ball joint (3) is excessively worn, remove the ball joint from the rack by securing the rack in a
vise. Using wood blocks between the rack and the jaws of the vise to protect the rack from damage,
loosen and remove the inner ball joint with a wrench (Figure 8-16, Page 8-13).
14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the housing (6) (Figure 8-17).
The bushing should not be replaced and is not available as a Service Part.
RACK AND PINION ASSEMBLY (SEE NOTE BELOW)
NOTE
• THESE ASSEMBLY INSTRUCTIONS FOR THE RACK AND PINION PERTAIN TO DS GASOLINE
VEHICLES SERIAL NO. AG9633-517735 AND LATER, AND DS ELECTRIC VEHICLES SERIAL
NUMBER A9640-533437 AND LATER. FOR EARLIER VEHICLES, GO TO PAGE 8-10.
1. Install a new tab washer (4) and a new inner ball joint (3) (Figure 8-17). Install the ball joint onto the
rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to pro-
tect the rack from damage (Figure 8-16, Page 8-13). Tighten the ball joint to 57 ft.lbs. (77.3 N-m).
2. Bend the edges of the tab washer (4) up against the ball joint (Figure 8-17).
3. Apply a liberal amount of grease to the teeth of the rack (17), then slide the rack through the bushing
(5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack.
CAUTION
• IN STEP FOUR, DO NOT PRESS AGAINST OUTER RACE OF THE BEARING.
4. If the bearing (9) 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 (10) (Figure 8-17).
5. If the bearing (7) is damaged, the bearing and housing must be replaced as an assembly (Figure 8-17).
6. Install the pinion (8) and bearing (9) assembly into the housing (6). 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 tapping 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.
7. Install the internal snap ring (11) (Figure 8-17).
8. Using a socket to apply pressure evenly, press in a new dust seal (12) (Figure 8-17) (See Figure 8-15,
Page 8-12).
9. Apply a small amount of grease to the rack guide where it comes into contact with the rack (17) (Figure
8-17).
10. Install a few drops of Loctite® 222 to the threads of the screw (16) (Figure 8-17).
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