%
Repair and Service Manual
)52176863(16,21$1'67((5,1*
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
699326
,QVWDOOWKHIURQWZKHHOV((/6$1'7,5(6VHF
WLRQ/RZHUWKHYHKLFOHSHUWKH6$)(7<VHFWLRQ
&KHFNWKHIURQWZKHHODOLJQPHQWDQGDGMXVWLIQHFHVVDU\
6HH
Wheel Alignment
5DFNDQG3LQLRQ8QLW'LVDVVHPEO\DQG
,QVSHFWLRQ
7RRO/LVW
4XDQWLW\
9LFH
6RFNHW
5DWFKHW
:UHQFK
:UHQFK
:LUH&XWWHU
5HWDLQLQJ5LQJ3OLHUV
6KRS7RZHO $5
&,7*2/LWKRSOH[031RJUHDVH$5
:LUH7LH/RQJ
:LUH7LH/RQJ
7RUTXH:UHQFKLQOEV
NOTICE: The rack and pinion gears are not service-
able items. If they are found to be damaged or
excessively worn, a new rack and pinion unit must
be installed.
To avoid damage to the aluminum
rack and pinion unit, secure the unit
in vice by the mounting ears only.
5HPRYHWKHUDFNDQGSLQLRQXQLWIURPWKHYHKLFOH$QFKRU
WKHXQLWLQYLFHE\FODPSLQJRQWKHPRXQWLQJHDUVRIWKH
XQLW
'LVDVVHPEOHWKHUDFNDQGSLQLRQXQLWE\UHPRYLQJ
VFUHZVDQGWHQVLRQHUWRUHOLHYHSUHVVXUHRQUDFN
DQGSLQLRQ)LJXUH
/RRVHQWKHMDPQXWDQGUHPRYHWKHEDOOMRLQWIURP
WKHUDFNH[WHQVLRQ&XWWKHZLUHWLHVVHFXULQJ
WKHEHOORZVRIIRIWKHUDFNH[WHQVLRQ3XOOWKHUDFN
IURPWKHXQLW
5HPRYHWKHSLQLRQVHDO6HH
Pinion Seal Replace-
ment
5HPRYHWKHLQWHUQDOUHWDLQLQJULQJIURPWKHUDFNDQG
SLQLRQXQLWSXOORXWWKHSLQLRQDQGEDOOEHDULQJDV
DQDVVHPEO\
)LJXUH5DFNDQG3LQLRQ8QLW'LVDVVHPEO\
&OHDQWKHUDFNSLQLRQDQGKRXVLQJ,QVSHFWWKHJHDU
WHHWKEHDULQJVXUIDFHVDQGWKHJUHDVHVHDOVXUIDFHVRI
WKHXQLWIRUH[FHVVLYHZHDURUGDPDJH,IDQ\GDPDJHRU
H[FHVVLYHZHDULVIRXQGWKHUDFNDQGSLQLRQXQLW
PXVWEH
UHSODFHGDVDQDVVHPEO\6HH
Rack and Pinion Unit
Replacement
,IWKHUDFNDQGSLQLRQLVVWLOOVHUYLFHDEOHFOHDQWKHFRPSR
QHQWVWKRURXJKO\DQGOXEULFDWHZLWK&,7*2/LWKRSOH[03
1RJUHDVH
$VVHPEOHWKHUDFNDQGSLQLRQXQLWE\LQVWDOOLQJWKHSLQLRQ
LQWKHUHYHUVHRUGHURIUHPRYDO0DNHVXUHWROXEULFDWHWKH
SLQLRQVHDOOLSSULRUWRLQVWDOOLQJWKHVHDO6HH
Pinion Seal
Replacement
,QVHUWWKHUDFNLQWRWKHUDFNDQGSLQLRQXQLW7XUQWKHSLQ
LRQFORFNZLVHWRKHOSSXOOWKHUDFNLQLIQHFHVVDU\,QVWDOO
WKHEHOORZV6HFXUHWRWKHUDFNH[WHQVLRQZLWKZLUHWLH
'RQRW
VHFXUHWKHODUJHHQGRIEHOORZVWRUDFNDQGSLQLRQ
XQLWXQWLOLQVWUXFWHGWRGRVRDIWHUVHWWLQJSURSHUUDFN
H[WHQVLRQWRUDFNDQGSLQLRQXQLWFOHDUDQFH,QVWDOOWHQ
VLRQHUDQGWLJKWHQEROWVWRKHWRUTXHYDOXHVSHFLILHG
EHORZ
7KUHDGWKHMDPQXWDQGWKHUDFNEDOOMRLQWWRWKHRULJLQDO
ORFDWLRQRQWKHUDFNH[WHQVLRQ6HWWKHMDPQXWKDQGWLJKW
,QVWDOOWKHUDFNDQGSLQLRQXQLWRQWKHYHKLFOH6HH
Rack
and Pinion Unit Replacement
,WHP
7RUTXH6SHFLILFDWLRQ
LQOEV1P
5
9
7
3
13
2
1
6
8
14
11
10
4
12