STEERING AND FRONT SUSPENSION
Rack and Pinion
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 7-9
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9. Install the universal joint onto the pinion and place a fork or a large open end wrench under the universal
joint (Figure 7-16, Page 7-10). Gently pry the pinion from the housing (Figure 7-17, Page 7-10).
10. Remove the U-joint from the pinion (3) (Figure 7-20, Page 7-11).
11. If the ball bearing (15) has been damaged, remove the c-type stop ring (16) (Figure 7-15, Page 7-9) and
press the bearing off (Figure 7-13, Page 7-9).
12. Inspect the bushing (17) and needle bearing (14) for excessive wear. If wear is excessive, replace the
steering box assembly (CCI 102010101) (Figure 7-20, Page 7-11).
13. Inspect the ball joints (9) for wear (Figure 7-20, Page 7-11). If one or both of the ball joints (9) are exces-
sively worn, remove the worn ball joint from the rack.
13.1. Secure the rack in a vise (Figure 7-18, Page 7-10). Use wood blocks between the rack and the
jaws of the vise to protect the rack from damage.
13.2. Tap the flange out of the notch in the rack (Figure 7-19, Page 7-10).
13.3. Using a wrench, remove the ball joint (9) from the rack (2) (Figure 7-20, Page 7-11).
14. Remove the rack (2) from housing (1) (Figure 7-20, Page 7-11).
Figure 7-12 Remove Pinion from Housing
Figure 7-13 Remove Bearing from Pinion
Figure 7-14 Remove Dust Seal
Figure 7-15 Pinion Snap Rings
PRESS RAM
PINION GEAR
BEARING
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