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7-2 Type: Rack and Pinion ............................................................. 7-2 TOOLS ........................................................................................... 7-3 SAFETY FIRST ............................................................................... 7-3 DESCRIPTION ................................................................................ 7-4 Steering .................................................................................... 7-4 REPAIR ........................................................................................... 7-5 INSPECTION ............................................................................ 7-5 REMOVAL ................................................................................ 7-5 RACK AND PINION REMOVAL ......................................... 7-5 STEERING WHEEL REMOVAL ........................................ 7-8 STEERING SHAFT REMOVAL ......................................... 7-8 INSTALLATION ............................................................................... 7-9 RACK AND PINION INSTALLATION ................................. 7-9 STEERING SHAFT INSTALLATION .................................7-10 STEERING WHEEL INSTALLATION ................................7-10 ADJUSTMENT ...................................................................7-11 BUSH HOG® UTILITY VEHICLE WORKSHOP MANUAL – SECTION 7: STEERING SYSTEM 7-2 TORQUE SPECIFICATIONS: COMPONENT TORQUE Tie Rod End Slotted Nut 30 lbs. ft. (41 Nm) Lug Nuts 50 lbs. ft. (68 Nm) STEERING WHEEL STEERING SHAFT BRACKET TIE ROD END TIE ROD END STEERING SHAFT ASSEMBLY RACK & PINION ASSEMBLY Steering Assembly Rack, Pinion and Tie Rod Ends Steering Wheel and Shaft LEFT TIE ROD END RIGHT TIE ROD END RIGHT SIDE BRACKET RACK SPECIFICATIONS TYPE: RACK AND PINION BUSH HOG® UTILITY VEHICLE WORKSHOP MANUAL – SECTION 7: STEERING SYSTEM TOOLS Common hand and shop tools can be used to remove and install steering system components serviced in the section. All special tools are listed below. Ball Joint Removal Tool (1.0-1.5” (25.4-38.1mm): Needed for removal of tie rod ends from the strut casting steering arm. Ball joint removal tools are commercially available in various sizes. SAFETY FIRST CAUTION Never work underneath a raised vehicle without adequate support. Use jack stands to prevent the vehicle from falling. A falling vehicle can cause severe personal injury or death. CAUTION When lifting a vehicle chock the wheels left on the ground to prevent the vehicle from rolling or sliding backward. BUSH HOG® UTILITY VEHICLE WORKSHOP MANUAL – SECTION 7: STEERING SYSTEM DESCRIPTION STEERING The UTV rack and pinion steering (Figure 1) is common in many automotive systems. The rack is a flat gear that extends outward from both ends of the assembly. A tie rod end connects the rack to the suspension strut assembly. NOTICE: The suspension struts are described in the Suspension Section of this manual. The pinion is a rotary gear attached to the steering shaft assembly. When the operator rotates the steering wheel the steering shaft turns the pinion gear which drives the rack in a back and forth movement. The rack and pinion gear set converts rotary steering wheel motion into linear motion needed to turn the wheels. The rack and pinion also provides gear reduction making it easier to steer the machine. The tie rods connect to a steering arm on the struts used for turning the strut. The wheels and hubs are mounted to the strut. See the section entitled Suspension for a description of the strut assemblies. Figure 1 Rack and Pinion Assembly TIE ROD END TIE ROD END LOCK NUT LOCK NUT RACK PINION GEAR DRIVE BUSH HOG® UTILITY VEHICLE WORKSHOP MANUAL – SECTION 7: STEERING SYSTEM REPAIR INSPECTION See the operator’s manual for recommendations on inspecting the steering system. Complaints of steering wheel hard to turn, hard steering, or loose steering can be a result of a bad pinion gear, bad rack, or bad tie rod ends. Use the recommendations in the operator’s manual for initial testing. Inspect the rack and pinion and tie rods for worn, loose, or damaged parts. Check for excessive wear in the steering bracket and upper steering shaft. Inspect the upper and lower steering shaft U-joints for excessive wear and damage. Replace the steering bracket bushings, steering bracket, upper and lower steering shafts as needed. REMOVAL CAUTION When working underneath a raised vehicle, always support the vehicle with jack stands to prevent the vehicle from falling. A falling vehicle can cause severe personal injury or death. RACK AND PINION REMOVAL 1. Using a floor jack, lift the machine and support with jack stands. 2. Turn the steering tires all the way right. 3. Remove the cotter pin from both tie rod end slotted hex nuts. Discard cotter pins. 4. Remove both tie rod slotted hex nuts (Figure 2). SLOTTED HEX NUT TIE ROD END Figure 2Tie Rod End BUSH HOG® UTILITY VEHICLE WORKSHOP MANUAL – SECTION 7: STEERING SYSTEM NO...