Club Car CARRYALL 1 2000, Maintenance And Service Manual

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STEERING AND FRONT SUSPENSION Rack and Pinion
2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-9
7
6. Remove the rack screw locknut (15), rack guide screw (16), rack guide pressure spring (14), and the
rack guide (13) (Figure 7-12, Page 7-10) .
7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off
the universal joint (Figure 7-12, Page 7-10) .
8. If necessary, remove the dust seal (12) (Figure 7-12, Page 7-10). See following NOTE.
9. Using snap ring pliers, remove the internal snap ring (11) (Figure 7-12, Page 7-10).
10. Install the universal joint onto the pinion and place a large open end wrench under the universal joint
(Figure 7-9, Page 7-8) . 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 7-12, Page 7-10)
and press the bearing off (Figure 7-10, Page 7-8) .
12. Remove retaining ring (19) and stop washer (18), then remove rack (17) from housing (6) (Figure 7-12,
Page 7-10) .
13. If the inner ball joint (3) is excessively worn, remove the ball joint and tab washer (4) from the rack by
securing the rack in a vise (Figure 7-11, Page 7-9) . 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.
14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly
(Club Car Part No. 101878302) (Figure 7-12, Page 7-10) .
RACK AND PINION ASSEMBLY
1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-11, Page 7-9) . 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 7-9) .
3. Apply a liberal amount of EP grease to the teeth of the rack (17), then slide the rack through the bush-
ing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Fig-
ure 7-12, Page 7-10)
.
Figure 7-11 Secure Rack in Vise
• IF THE DUST SEAL (12) IS REMOVED, REPLACE WITH A NEW ONE (FIGURE 7-12, PAGE 7-10).
SECURE RACK USING
WOOD BLOCKS AND A VISE
TAB WASHER
INNER
BALL
JOINT
3
4
NOTE