Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2009 ZAP XLFACTORY OEM SERVICE PROCEDURE
Steering Gear Assembly Components: Notes
| Item | Description |
|---|---|
| 1 | Rubber boot of steering gear |
| 2 | Mounting bracket of steering gear |
| 3 | Outer tie rod assembly |
| 4 | Lower driving shaft assembly |
| 5 | Flexible connection assembly |
| 6 | Steering bevel pinion assembly |
| 7 | Spline joint |
| 8 | Rubber sleeve assembly |
NOTE:
It is necessary to take off clutch release cable when disassembling the front axle welded assembly. Adjust the clutch release cable after installing front axle welded assembly.
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.