Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 97 / 544

Page 8-13
G
E
8
20. Adjust the steering gear (See Page 8-6).
RACK AND PINION DISASSEMBLY (SEE NOTE BELOW)
1. Remove the ball joint (23) (Figure 8-17, Page 8-14) and inspect it for excessive wear (See Figure 8-6,
Page 8-7).
2. Remove the drag link (28) (Figure 8-17, Page 8-14).
3. Remove both bellows clamps (2) (Figure 8-17, Page 8-14).
4. Remove the hex nut (29) and slide off the dust seal bellows (1) (Figure 8-17, Page 8-14).
5. Remove the retaining ring (21), then slide off dust seal bellows (20) (Figure 8-17, Page 8-14).
6. Remove the rack guide screw (16), rack screw lock nut (15), rack guide pressure spring (14), and the
rack guide (13) (Figure 8-17, Page 8-14).
7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off
the universal joint.
• TO BE SURE THAT THE RACK AND PINION IS WORKING PROPERLY, TURN THE UNIVERSAL
JOINT ASSEMBLY BY HAND. IF IT IS TOO TIGHT, LOOSEN THE LOCK NUT (22) AND BACK THE
SCREW (21) OFF 1/4 TURN. THEN TIGHTEN THE LOCK NUT (22) TO 40 FT.LBS. (54 N-M) (FIG-
URE 8-7, PAGE 8-8).
• THESE INSTRUCTIONS FOR RACK AND PINION DISASSEMBLY PERTAIN TO GASOLINE VEHI-
CLES SERIAL NUMBER AG9633-517735 AND LATER AND TO ELECTRIC VEHICLES SERIAL
NUMBER A9640-533437 AND LATER. FOR EARLIER VEHICLES, GO TO PAGE 8-9.
• THE BALL JOINT (23) (FIGURE 8-17, PAGE 8-14) HAS LEFT HAND THREADS.
FIGURE 8-16
NOTE
NOTE
CAUTION
SECURE RACK USING
WOOD BLOCKS AND A VISE
LOCKWASHER
INNER
BALL
JOINT