Rack And Pinion Assembly - Club Car Turf 1 Service Manual

STEERING AND FRONT SUSPENSION
4
TAB WASHER
WOOD BLOCKS
Figure 7-11 Secure Rack in Vise
14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (CC
P/N 101878302) (Figure 7-8, Page 7-9).

RACK AND PINION ASSEMBLY

1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-11, Page 7-11). 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
protect the rack from damage. Tighten the ball joint to 60 ft-lb (81 N·m).
2. Bend the edges of the tab washer (4) up against the ball joint (3) (Figure 7-11, Page 7-11).
3. Apply a light coating of EP 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 (Figure 7-8,
Page 7-9).
CAUT ION
• In step 4, do not press against the 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 7-8, Page 7-9). See pre-
ceding CAUTION.
5. If the needle bearing (7) is damaged, the steering box assembly (CC P/N 101878302) must be replaced
(Figure 7-8, Page 7-9).
6. Install pinion (8) and bearing (9) assembly into the housing (6) (Figure 7-8, Page 7-9). 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 following CAUTION.
CAUT ION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small
bearing could be damaged.
3
INNER BALL
JOINT
2012 Turf/Carryall Vehicle Maintenance and Service Manual
7
Rack and Pinion
Page 7-11