Cushman SHUTTLE 4X - FRONT SUSPENSION AND STEERING; MAINTENANCE

TABLE OF CONTENTS FOR SECTION ‘E’
SECTION TITLE PAGE NO.
Page E-i
Repair and Service Manual
FRONT SUSPENSION AND STEERING
MAINTENANCE.............................................................................................................E - 2
Lubrication ............................................................................................................................E - 2
Wheel Bearing and King Pin Bushing Inspection..................................................................E - 2
Wheel Bearing Packing.........................................................................................................E - 2
Wheel Bearing Adjustment ................................................................................................... E - 3
Wheel Alignment...................................................................................................................E - 3
FRONT SUSPENSION ..................................................................................................E - 5
Front Shock Absorber Replacement.....................................................................................E - 5
Front Axle Replacement .......................................................................................................E - 6
Axle Linkage Rod Replacement............................................................................................ E - 6
Front Spring Replacement....................................................................................................E - 7
Hub Replacement.................................................................................................................E - 8
Wheel Bearing and Race Replacement................................................................................E - 8
STEERING...................................................................................................................E - 10
Rack Ball Joint Replacement..............................................................................................E - 10
Tie Rod Inspection/Replacement........................................................................................E - 11
Bellows Replacement .........................................................................................................E - 12
Pinion Seal Replacement....................................................................................................E - 12
Spindle Replacement..........................................................................................................E - 13
Rack and Pinion Unit Disassembly and Inspection.............................................................E - 14
Rack and Pinion Unit Replacement ....................................................................................E - 15
Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance...........................E - 15
Steering Wheel Replacement .............................................................................................E - 16
Steering Shaft and Column Replacement........................................................................... E - 17
LIST OF ILLUSTRATIONS
Fig. 1 Axle Mounted Steering and Front Suspension ......................................................................E - 1
Fig. 2 Lubrication Points ..................................................................................................................E - 2
Fig. 3 Bearing Adjustment ...............................................................................................................E - 3
Fig. 4 Wheel Alignment....................................................................................................................E - 4
Fig. 5 Disconnect Intermediate Shaft to Center Steering Wheel .....................................................E - 4
Fig. 6 Front Suspension Components .............................................................................................E - 5
Fig. 7 Axle Linkage Rod Replacement ............................................................................................E - 7
Fig. 8 Front Axle Alignment .............................................................................................................E - 8
Fig. 9 Hub Replacement..................................................................................................................E - 8
Fig. 10 Seal Installation ...................................................................................................................E - 8
Fig. 11 Wheel Bearing Replacement...............................................................................................E - 9
Fig. 12 Steering Components........................................................................................................E - 10
Fig. 13 Rack Ball Joint Installation.................................................................................................E - 11
Fig. 14 Tie Rod Replacement........................................................................................................ E - 11
Fig. 15 Bellows Replacement ........................................................................................................E - 12
Fig. 16 Pinion Seal Replacement ..................................................................................................E - 13
Fig. 17 Removing Brake Caliper.................................................................................................... E - 13
Fig. 18 Spindle Replacement.........................................................................................................E - 14
Fig. 19 Rack and Pinion Unit Disassembly....................................................................................E - 14
Fig. 20 Spindle Contact with Front Axle.........................................................................................E - 16
Fig. 21 Checking Gap....................................................................................................................E - 16
Fig. 22 Clipboard Removal ............................................................................................................E - 16
Fig. 23 Steering Wheel Replacement............................................................................................E - 17
Fig. 24 Steering Shaft and Column................................................................................................E - 17
Fig. 25 Small Retaining Ring Orientation.......................................................................................E - 18