Club Car 1996 DS Golf Car Gasoline, Service Manual

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Page 7-8
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Brake Assembly Removal, Continued:
2. Loosen the equalizer retaining nuts (1) on the equalizer rod (2) to slightly loosen the brake cable (Fig-
ure 7-2, Page 7-3).
3. Remove the rear wheels and then the brake drums.
4. Remove the axle. See CAUTION below.
4.1. Using snap ring pliers, remove the axle retaining ring (1) (Figure 7-3, Page 7-3).
4.2. Pull the axle shaft (2) from the axle tube (Figure 7-3, Page 7-3).
5. Remove cotter pin (13) and clevis pin (12) from brake cable (Figure 7-1, Page 7-2).
6. Remove 4 bolts (11) (Club Car Part No. 1014153) and lock nuts (10) (Club Car Part No. 1013924) that
mount the brake assembly to the transaxle.
7. Brake assembly can now be removed from transaxle.
Installation of Brake Assembly On Axle Tube
1. Install in reverse order of disassembly.
2. Be sure bolts (11) (Club Car Part No. 1014153) and lock nuts (10) (Club Car Part No. 1013924) are
used to mount the brake assembly (Figure 7-1, Page 7-2).
3. Torque bolts to 27-33 ft.lbs. (36/45 N-m).
4. Adjust brakes as previously described in this section.
• 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.
• SOME BRAKE SHOES CONTAIN ASBESTOS FIBER, AND ASBESTOS DUST IS CREATED
WHEN THESE BRAKE MECHANISMS ARE HANDLED. WEAR APPROVED EYE AND RESPIRA-
TORY PROTECTION WHEN DISASSEMBLING AND CLEANING BRAKE MECHANISMS. INHALA-
TION OF ASBESTOS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. DO NOT
USE COMPRESSED AIR OR AEROSOL SPRAYS TO CLEAN THE BRAKE MECHANISM. CLEAN
BRAKE MECHANISMS USING THE NEGATIVE PRESSURE ENCLOSURE/HEPA VACUUM SYS-
TEM OR LOW PRESSURE/WET CLEANING METHOD PER OSHA/29 CFR - 1910.1001.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• REMOVE ONLY ONE AXLE SHAFT AT A TIME. COMPLETE BRAKE CLEANING OR REPAIR
PROCEDURE ON ONE SIDE OF THE VEHICLE AND INSTALL THE AXLE SHAFT BEFORE
BEGINNING PROCEDURE ON THE OTHER SIDE OF THE VEHICLE.
• BE SURE RETAINING RING IS PROPERLY SEATED IN GROOVE. IF RING IS NOT PROPERLY
INSTALLED, THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE
THE AXLE ASSEMBLY AND OTHER COMPONENTS. LOSS OF CONTROL OF THE VEHICLE
COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WARNING
CAUTION
WARNING