Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 541 / 544

Page 25-3
E
25
the axle tubes (Figure 25-2), then lower the vehicle to let the jackstands support the vehicle. See
WARNING below.
2. Remove the tire and wheel assembly on the side from which the leaf spring is to be removed.
3. Remove the lower nut (3) and bolt (2) from the rear shackle (6) (Figure 25-1, Page 25-1).
4. Remove the cotter pin (1) and then the clevis pin (2) at the brake lever/cable connection, and then pull
the clevis (3) away from the brake lever (Figure 25-4, Page 25-4).
5. Remove the nut (12), cup washer (10), and bushing (11) from the bottom side of the shock absorber.
Compress the shock absorber (pushing upwards) to move it out of the way (Figure 25-1, Page 25-1).
6. Remove the two nuts (16) and lock washers (15) from the U-bolts at the spring plate (17). Remove the
spring plate, and then the leaf spring will swing down (Figure 25-5, Page 25-4).
7. Remove the nut (3) and bolt (2) attaching the front of the leaf spring to the vehicle frame. The spring
can now be removed (Figure 25-1, Page 25-1).
8. Inspect the bushings (4) and spacers (5) in the leaf spring eyes and replace them if they are worn or
damaged (Figure 25-1, Page 25-1).
INSTALLING THE REAR LEAF SPRINGS
1. To install the rear leaf springs, reverse the removal procedure. See CAUTION below and CAUTION
and NOTE on page 25-4.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
FIGURE 25-2 FIGURE 25-3
• WHEN PLACING THE TRANSAXLE ON THE LEAF SPRING, BE SURE TO POSITION THE
LOCATING BOLT ON THE SPRING IN THE LOCATING HOLE IN THE TRANSAXLE SADDLE.
WARNING
Club Car
CAUTION