Cushman TURF-TRUCKSTER, Service & Repair Manual, Page: 136 / 263

RACK PISTON (See Figure 6D-5)
1. Remove the retaining ring, housing end plug and
O-ring.
2. Remove the rack piston plug.
3. Insert a special ball retainer tool (#J-21552, avail-
able from General Motors Saginaw Gear deal-
ers/distributors) into the rack piston. Hold the tool
tightly against worm while turning stub shaft coun-
terclockwise. The rack piston will be forced onto
the tool. Remove the rack piston and ball retainer
from the gear housing together.
4. Remove the ball retainer, tool, clamp screws,
clamp, ball retainer and balls from the rack piston.
5. Remove rack piston ring and O-ring. Replace
O-ring and piston ring.
6. If no further disassembly is required, proceed with
Steps 7 thru 14.
7. Coat the rack piston ring and O-ring with power
steering fluid and install on the rack piston.
8. Insert the worm gear (see Figure 6D-1) into the
rack piston. Turn the worm gear until the groove
in the worm is aligned with the lower ball return
guide hole (see Figure 6D-5).
NOTE
The black balls are smaller than the silver balls.
The black and silver balls must be installed alter-
nately into the rack piston and return guide to
maintain rack piston to worm gear preload.
9. Lubricate balls with power steering fluid. Install
balls through ball return guide hole, while rotating
worm counterclockwise.
10. Alternately install the remainder of the balls in the
ball retainers. Use anhydrous calcium grease to
retain balls in ball retainers. Mount retainers (with
bolts inserted) on rack piston and secure with
clamp. Tighten clamp screws to 4 ft-lbs. (5 N.m).
11. Insert the ball retainer tool (see inset Figure 6D-5)
into the rack piston. Hold the tool tightly against
the worm gear while turning the stub shaft clock-
wise to remove the worm gear.
12. Refer to Figure 6D-7, install bearing races and
thrust bearings, worm gear, stub shaft and valve
assembly, removing the ball retainer tool (inset
Figure 6D-5) as the worm gear is turned into the
rack piston.
13. Install the rack piston plug, end plug, O-ring, end
plug and retaining ring.
14. Perform adjustments at end of this section.
STEERING
SECTION 6D. STEERING GEAR
6D-3
6D
Figure 6D-4. Pitman Shaft and Cover