Club Car IntelliTach XRT 1550, Maintenance And Service Manual

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STEERING AND FRONT SUSPENSION Rack and Pinion
2007 Carryall 295/295 SE & XRT 1550/1550 SE Gasoline, Diesel and IntelliTach M & S Manual Page 7-9
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RACK AND PINION ASSEMBLY
1. Apply a liberal amount of EP grease to the teeth of the rack (2), then slide the rack through the bushing
(17) and housing (1) (Figure 7-16, Page 7-8) .
CAUT ION
• In step 2, do not press against the outer race of the bearing.
2. If the pinion bearing (15) was removed, grease a new bearing before installation. Press the new bearing
onto the pinion shaft, and exert all pressure on the inner race. Then install the C-type stop ring (16). See
preceding CAUTION.
3. Install the pinion (3) and bearing (15) assembly into the housing (1). Ensure the gear teeth in the rack
(2) will mesh with the gear teeth on the pinion. It may be necessary to rotate the rack slightly and lightly
tap 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.
4. Install the snap ring (4).
5. Use a socket to apply pressure evenly, and press in a new dust seal (Figure 7-17, Page 7-9) .
6. Apply a small amount of grease to the rack guide (5) where it contacts the rack (2) (Figure 7-16,
Page 7-8) .
7. Install the ball joints (9) onto the rack (2). Secure the rack in a vise with wood blocks between the rack
and the jaws of the vise to protect the rack from damage, and tighten the ball joints to 60 ft-lb (81 N·m)
(Figure 7-20, Page 7-10) .
8. Tap a flange into the notch on the rack.
9. Place a few drops of Loctite 222 on the threads of the screw (7) (Figure 7-18, Page 7-9) .
Figure 7-17 Press In Dust Seal Figure 7-18 Rack and Pinion Adjustment
RUBBER MALET
15/16-INCH DEEP WELL
SOCKET
DUST SEAL
IN PLACE
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