Rack And Pinion Assembly - Club Car 2005 precendent Maintenance And Service

7
STEERING AND FRONT SUSPENSION

RACK AND PINION ASSEMBLY

1. Apply a liberal amount of EP grease to the teeth of the rack (18), then slide the rack through the bushing
(7) and housing (17) (Figure 7-5, Page 7-6).
CAUT ION
• In step 2, do not press against the outer race of the bearing.
2. If the pinion bearing (4) was removed, grease a new bearing before installation. Press new bearing onto
pinion shaft, exerting all pressure on the inner race. Then install the C-type stop ring (3). See previous
CAUTION.
3. Install pinion (5) and bearing (4) assembly into the housing (17). 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 pin-
ion-bearing assembly with a rubber mallet. See following CAUTION.
CAUT ION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small
bearing could be damaged.
4. Install the large snap ring (2).
5. Use a socket to apply pressure evenly and press in a new dust seal (Figure 7-10, Page 7-9).
6. Apply a small amount of grease to the rack guide (16) where it comes into contact with the rack (18)
(Figure 7-5, Page 7-6).
7. Install the ball joints (8) onto the rack (18) 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. Tighten the ball joints to 60 ft-lb (81 N·m).
8. Tap a flange into the notch on the rack (Figure 7-11, Page 7-9).
9. Place a few drops of Loctite 222 to the threads of the screw (14) (Figure 7-5, Page 7-6).
10. Install the rack guide (16), pressure spring (15) and screw (13). The screw should be threaded-in until
it bottoms out and then backed out 1/4 turn (Figure 7-5, Page 7-6).
11. Insert a 3/8-inch, 1/4-drive, deep-well socket into the steering column end of the universal joint (2) and
tighten the bolts (1) to 15 ft-lb (20.3 N·m) (Figure 7-13, Page 7-9).
12. Use a torque wrench connected to the 3/8-inch deep-well socket to measure the resistance of the rack
and pinion. Rotational resistance should measure 7 to 15 in-lb (0.8 to 1.7 N·m).
13. If measured resistance is not 7 to 15 in-lb (.8 to 1.7 N·m), adjust the screw (13) until correct setting is
achieved. Tighten the nut (14) to 28 ft-lb (38 N·m) (Figure 7-12, Page 7-9).
NOTE: When tightening the nut (14) make sure the screw (13) does not change adjustment (Figure 7-12,
Page 7-9).
14. Install the two dust seal bellows (9) (Figure 7-5, Page 7-6).
15. Install new bellows clamps (wire ties) (10 and 21).
16. Install the tie rod ends (12) to each end of rack (18). Tighten the tie rod end jam nuts (11) to 20 ft-lb
(27 N·m) (Figure 7-5, Page 7-6).
Page 7-8 2005 Precedent Gasoline Golf Car Maintenance and Service Manual
Rack and Pinion