E-Z-GO MPT 800, Руководство по ремонту и обслуживанию техника

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FRONT SUSPENSION AND STEERING
Page E-15
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
ion unit until instructed to do so after setting proper rack
extension-to-rack and pinion unit clearance. Install ten-
sioner and tighten bolts (13) to 100 - 120 in. lbs. (115 -
138 kg cm) torque. Thread jam nut and rack ball joint to
original location on rack extension and set jam nut hand
tight.
Install rack and pinion unit on vehicle. See ‘Rack and
Pinion Unit Replacement’ on page E-15.
After replacing or servicing steering
components, always verify that an 1/8"
gap exists between large hex of rack extension and rack and pin-
ion unit when steering is turned fully to the right forcing passen-
ger spindle arm against front axle.
Set proper rack extension-to-rack and pinion unit clear-
ance. See ‘Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance’ on page E-15.
Rack and Pinion Unit Replacement
Tool List Qty. Required
Socket, 13 mm, 3/8" drive ........................................... 1
Ratchet, 3/8" drive....................................................... 1
Needle nose pliers ...................................................... 1
Wrench, 11/16"............................................................ 1
Ball joint separator ...................................................... 1
Plastic faced hammer ................................................. 1
Wrench, 5/8" ............................................................... 1
Socket, 5/8", 1/2" drive................................................ 1
Ratchet, 1/2" drive....................................................... 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Socket, 11/16", 1/2" drive ............................................ 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
To remove rack and pinion unit (12) (Ref Fig. 12 on page
E-10), loosen front wheels and lift and support front of
vehicle per SAFETY section. Remove front wheels.
Remove bolt (13) and washer (14) securing intermediate
shaft (15) to rack and pinion unit (12).
Remove cotter pin (2) and loosen castellated nut (3) until
rack ball joint (1) threads are protected. Using a ball joint
separator as a lever, apply pressure to ball joint and tap
nut with plastic faced hammer to release ball joint from
passenger side spindle arm. Remove nut from ball joint
and ball joint from spindle arm.
Remove the three lock nuts (18) securing rack and pinion
unit to front axle and discard nuts. The rack and pinion
unit can now be removed from vehicle. Retain washers
(19), spacers (20) and the two bolts (16) for assembly.
Replace rack and pinion unit in reverse order of removal.
Use new lock nuts (18) and tighten them to 35 - 50 ft. lbs.
(50 - 70 Nm) torque.
Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque
and continue to tighten as needed to insert new cotter
pin. Maximum torque is 50 ft. lbs. (70 Nm).
Tighten bolt (13) securing intermediate shaft to pinion to
155 - 215 in. lbs. (180 - 250 kg cm) torque.
After replacing or servicing steering
components, always verify that an 1/8"
gap exists between large hex of rack extension and rack and pin-
ion unit when steering is turned fully to the right forcing passen-
ger spindle arm against front axle.
Set proper rack extension-to-rack and pinion unit clear-
ance. See ‘Checking/Adjusting Rack Extension-to-Rack
and Pinion Unit Clearance’ on page E-15.
Install front wheels per WHEELS AND TIRES section
and lower vehicle per SAFETY section.
Check front wheel alignment and adjust if necessary.
See ‘Wheel Alignment’ on page E-3.
Checking/Adjusting Rack Extension-to-
Rack and Pinion Unit Clearance
Tool List Qty. Required
Wrench, 11/16" ............................................................ 1
Wrench, 3/4"................................................................ 1
Wrench, 1/2"................................................................ 1
Wire cutter ................................................................... 1
Washer, 1/8" thick........................................................ 1
Crowfoot socket, 3/4", 1/2" drive ................................. 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Wire tie, 10" long ......................................................... 1
Check for proper rack extension-to-rack and pinion unit
clearance by first turning steering wheel fully to the right.
The rear spindle arm on the passenger side must rest
against the front axle (Ref Fig. 20 on page E-16). If it
does not, all adjustment is made at the rack ball joint (6)
(Ref Fig. 19 on page E-14). Loosen jam nut (5) at rack
ball joint and use wrench to thread shaft of rack exten-
sion (7) further into rack ball joint. This will provide more
travel for the steering wheel to be turned to the right.
With spindle arm resting against front axle, cut wire tie
(14) securing bellows (9) to rack and pinion unit (1) and
slide bellows away from rack and pinion unit to see large
hex of rack extension. An 1/8" gap should exist between
the large hex and the end of the rack and pinion unit.