Rack And Pinion Installation - Club Car 2008 Turf Maintenance And Service Manual

9
STEERING AND FRONT SUSPENSION
Rack and Pinion Assembly, Continued:
7. Install the internal snap ring (11) (Figure 9-12, Page 9-10).
8. Using a socket to apply pressure evenly, press in a new dust seal (Figure 9-13, Page 9-11).
9. Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17)
(Figure 9-12, Page 9-10).
10. Place a few drops of Loctite
11. Install the rack guide (13), pressure spring (14), and screw (16). The screw should be threaded in until
a rotational torque of 10 in-lb (1.13 N·m) is achieved (Figure 9-12, Page 9-10).
11.1. Reposition the rack and pinion in a vise.
11.2. Insert a 3/8-inch deep well socket into the steering column end of the universal joint (2) and tighten
the bolt (1) to 15 ft-lb (20.3 N·m) (Figure 9-15, Page 9-11).
11.3. 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).
11.4. If measured resistance does not equal 7 to 15 in-lb, loosen the lock nut (15) and tighten the screw
(16) until it bottoms out, then back the screw off one quarter turn. Tighten the lock nut to 28 ft-lb (38
N·m) (Figure 9-14, Page 9-11). See following NOTE.
NOTE: When tightening the lock nut (15) make sure the screw (16) does not change adjustment
(Figure 9-14, Page 9-11).
12. Install the dust seal bellows (20) and retaining ring (21) (Figure 9-12, Page 9-10).
13. Install the dust seal bellows (1) and hex nut (29) (Figure 9-12, Page 9-10).
14. Install the universal joint on the pinion. Tighten the bolt to 15 ft-lb (20 N·m).
15. Install new bellows clamps (wire ties) (2) (Figure 9-12, Page 9-10).
16. Install the drag link (28) by fully threading the ground end into the inner ball joint (3). See following CAU-
TION.
CAUT ION
• The ball joint (23) (Figure 9-12, Page 9-10) has left-hand threads.
• The tie rod and drag link have right-hand threads on one end and left-hand threads on the
other end. Right-hand threads are identified by a groove in the tie rod or drag link.
17. Install the ball joint (23) (Figure 9-12, Page 9-10). See preceding CAUTION.

RACK AND PINION INSTALLATION

1. Position the steering gear box assembly on the shock and gear support and install the bolts (30), wash-
ers (31), and nuts (32). Do not tighten the mounting bolts (Figure 9-12, Page 9-10).
2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound
to the splined end of the steering column shaft.
3. Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the
shaft into the upper universal joint. Install the bolt and lock washer on the upper universal joint and tighten
it to 15 ft-lb (20 N·m).
4. Tighten the steering rack mounting bolts (30) to 22 ft-lb (29.8 N·m) (Figure 9-12, Page 9-10).
5. Adjust the steering. See Steering Adjustment on page 9-7.
Page 9-12 2008 Turf/Carryall Vehicle Maintenance and Service Manual
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222 to the threads of the screw (16) (Figure 9-12, Page 9-10).
Rack and Pinion