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Club Car CARRYALL 1 2000, Maintenance And Service Manual

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Summary of Contents for CARRYALL 1 2000

Page 1: ...TURF 1 TURF 2 TURF 6 CARRYALL 1 CARRYALL 2 CARRYALL 2 PLUS AND CARRYALL 6 VEHICLES MANUAL NUMBER 102067502 EDITION CODE 0500C0312B 2000 MAINTENANCE S E RV I C E MANUAL...

Page 2: ......

Page 3: ...nd or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained technician It is the policy of Club Car Inc to assist its distributors and deale...

Page 4: ...ILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THIS MANUAL DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE OVERLOADING ABUS...

Page 5: ...itch 3 3 Forward Reverse Control 3 4 Accelerator Pedal 3 5 Brake Pedal 3 5 Park Brake Pedal 3 5 Neutral Lockout 3 6 Choke 3 7 Oil Light 3 8 Fuel Hour Gauge 3 8 Battery Warning Light 3 8 Driving Instru...

Page 6: ...urf 6 and Carryall 6 4 7 Flat Bed Removal 4 7 Flat Bed Installation 4 7 Flat Bed Trim Turf 6 and Carryall 6 4 7 Flat Bed Trim Removal 4 7 Flat Bed Trim Installation 4 10 Access Door Turf 6 and Carryal...

Page 7: ...ECTION 6 WHEEL BRAKE ASSEMBLIES General Information 6 2 Brake Shoe Removal 6 3 Brake Assembly Cleaning Self Adjusting Brakes 6 4 Brake Shoe Installation Self Adjusting Brakes 6 6 Brake Adjustment Self...

Page 8: ...ion Assembly 7 9 Rack and Pinion Installation 7 12 Tie Rod and Drag Link 7 12 Tie Rod and Drag Link Removal 7 12 Tie Rod and Drag Link Installation 7 13 Front Suspension 7 13 Lubrication 7 13 Wheel Al...

Page 9: ...8 3 SECTION 9 REAR SUSPENSION General Information 9 1 Shock Absorbers 9 2 Inspecting and Removing Shock Absorbers 9 2 Installing Shock Absorbers 9 2 Multi Leaf Springs 9 2 Removing the Multi Leaf Spr...

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Page 11: ...an be found throughout this manual Also other specific warnings appear throughout this manual and on the vehicle A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR D...

Page 12: ...ON OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR HANDLING OF THE VEHICLE OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CHEC...

Page 13: ...1 3 AFTER DISCONNECTING BATTERIES DISCHARGE THE CONTROLLER AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD REVERSE HANDLE IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KE...

Page 14: ...1...

Page 15: ...r with float bowl fixed jets fuel filter and impulse fuel pump Governor Automatic ground speed sens ing internally geared in unitized transaxle Ignition Transistor electronic ignition with electronic...

Page 16: ...27 cm 49 25 in 120 cm 49 25 in 120 cm Overall Height At Steering Wheel 48 in 122 cm 48 in 122 cm 48 in 122 cm 48 in 122 cm 48 in 122 cm 48 in 122 cm 48 in 122 cm Wheelbase 65 5 in 166 cm 65 5 in 166 c...

Page 17: ...10 9 in 124 x126x28 cm 48 8 in x 49 8 in x 10 9 in 124 x126x28 cm 48 8 in x 49 8 in x 10 9 in 124 x126x28 cm 64 2 in x 44 in x 18 5 in 163 x 112 x 47 cm 64 2 in x 44 in x 18 5 in 163 x 112 x 47 cm Loa...

Page 18: ...2...

Page 19: ...l should become familiar with the controls and operation and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery Use the following checklist...

Page 20: ...If the brake pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop have the brake system checked and adjusted as required Brake adjustment must be maintained so the brak...

Page 21: ...e 3 4 Page 3 4 DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS WHICH IS AN ODORLESS DEADLY POISON BEFORE ALLOWING THE VEHICL...

Page 22: ...hen in reverse The reverse buzzer will sound as a warning when the forward reverse handle is in the REVERSE position Pedal Start Vehicles When the Forward Reverse handle is in the straight up or N NEU...

Page 23: ...r pedal As the accelerator pedal is depressed speed will increase until full speed is reached When the accelerator is released the engine will idle BRAKE PEDAL The brake pedal is the large pedal on th...

Page 24: ...wing WARNING and NOTE Pedal Start vehicles When the cam is in the SERVICE position it will allow the technician to run the engine in NEUTRAL to perform certain maintenance and or repair functions With...

Page 25: ...the seat support panel below and to the left of the driver s left knee If the vehicle is hard to start in cool or cold temperatures activate the choke Turf 1 and Carryall 1 Push in the choke cover to...

Page 26: ...ehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem The battery warning light is controlled by the PowerDrive onboard computer When t...

Page 27: ...l Communication Display Module which provides information on the condition of the vehicle and batteries DRIVING INSTRUCTIONS ONLY LICENSED DRIVERS SHOULD BE ALLOWED TO DRIVE THIS VEHICLE BEFORE ALLOWI...

Page 28: ...rd Reverse handle is in the NEUTRAL position 5 2 Depress and hold the brake pedal 5 3 Turn the key all the way to the START position and release after engine is started The engine will idle 5 4 While...

Page 29: ...STOP RUNNING KEY START VEHICLE IF THE ACCELERATOR PEDAL IS DEPRESSED WHILE THE FORWARD REVERSE HANDLE IS IN NEUTRAL OR IF YOU TRY TO SHIFT FROM FORWARD TO REVERSE WHILE THE ACCELERATOR PEDAL IS DEPRE...

Page 30: ...ORE LOADING THE VEHICLE DO NOT ALLOW PASSENGERS IN THE CARGO BED DO NOT EXCEED THE RATED CAPACITY OF THE VEHICLE 800 LB 363 KG FOR THE TURF 1 AND CARRYALL 1 1200 LB 544 KG FOR THE TURF 2 CARRYALL 2 AN...

Page 31: ...ITION AND LATCHED SECURELY WHILE THE VEHICLE IS IN MOTION TO AVOID SHIFTING THE VEHICLE LOAD AND POSSIBLY OVERTURNING THE VEHICLE AVOID SUDDEN STARTS SUDDEN STOPS AND ABRUPT TURNS THE CARGO S CENTER O...

Page 32: ...D TRAILER ALWAYS USE AN APPROVED TRAILER THAT HAS A LOAD RATING OF AT LEAST 1600 LB 727 KG TURF 1 TURF 2 CARRYALL 1 CARRYALL 2 AND CARRYALL 2 PLUS OR 2000 LB 909 KG FOR TURF 6 AND CARRYALL 6 PER VEHIC...

Page 33: ...through the spark plug hole Rotate the engine crankshaft by hand several times and then re install spark plug 5 Inflate tires to rated capacity See Section 8 Wheels and Tires 6 Grease front suspensio...

Page 34: ...ist See Page 3 1 STORAGE ELECTRIC VEHICLE Read DANGER and WARNING in Section 1 Safety Figure 3 19 Fuel Shut Off Valve ON Position Figure 3 20 Incorrect Fuel Shut Off Valve Setting WHEN STARTING THE EN...

Page 35: ...event the vehicle from rolling 9 Keep batteries fully charged during storage See Section 13 Batteries in the appropriate mainte nance and service supplement Leave PowerDrive chargers plugged in during...

Page 36: ...3...

Page 37: ...VED FOR DUST AND PAINT MIST WHEN CUTTING SANDING PAINTING OR REPAIRING BODY PANELS TURN KEY SWITCH OFF PLACE FORWARD REVERSE HANDLE IN THE NEUTRAL POSITION AND REMOVE KEY BEFORE SERVICING THE VEHICLE...

Page 38: ...e necessary to move the gun closer to the body to fade the streak but under no circumstance should the gun be held closer than 6 inches 15 cm to the body MINOR IMPACT DAMAGE DEFORMATIONS Minor impact...

Page 39: ...nd body repair shop with experience repairing TPO bodies FRONT BODY Read DANGER and WARNING on page 4 1 FRONT BODY REMOVAL 1 Remove screws 8 and locknuts 9 and lift front bumper 6 from vehicle frame F...

Page 40: ...r trim 13 and remove from vehicle Figure 4 1 Page 4 4 FRONT BODY INSTALLATION 1 Install front body 12 under trim 13 align holes and finger tighten screws 14 holding front body against frame Figure 4 1...

Page 41: ...2 CARRYALL 1 2 AND 2 PLUS TILT BED REMOVAL For Turf 6 and Carryall 6 Flat Bed Removal see Page 4 7 1 Turf 2 Carryall 2 and 2 Plus Only Raise bed and secure prop rod 17 in prop rod track 18 Hold bed se...

Page 42: ...Vehicle Maintenance and Service Manual 4 Figure 4 2 Tilt Bed Turf 1 2 Carryall 1 2 and 2 Plus TYPICAL 2 PLACES 8 9 3 10 25 TYPICAL 2 PLACES 18 TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 12 1 4 TYPICAL 4 PLAC...

Page 43: ...x 3 3 8 bolts 9 Lift bed from vehicle Figure 4 3 Page 4 8 FLAT BED INSTALLATION 1 Place bed on vehicle with bed front edge 1 inch from seat back support panel 28 and open access door 5 Figure 4 3 Pag...

Page 44: ...head bolt 4 flat washer 5 and locknut 6 from front of left hand trim strip 1 Figure 4 4 Page 4 9 7 Remove two 5 16 x 1 hex head bolts and locknuts from each of the three stake side brackets 7 on left...

Page 45: ...Manual Page 4 9 4 Figure 4 4 Flat Bed Trim Access Door and Side Door Turf 6 and Carryall 6 3 TYPICAL 16 PLACES 7 TYPICAL 8 PLACES 3 2 6 4 1 TYPICAL 4 PLACES 6 4 5 TYPICAL 2 PLACES AT DOOR 25 24 23 27...

Page 46: ...RRYALL 6 SIDE DOOR REMOVAL 1 Lift door latch lever 27 rotate 180 degrees and open side door Figure 4 4 Page 4 9 2 Remove two 1 4 x 5 8 bolts 26 and locknuts 25 from door hinge Figure 4 4 Page 4 9 3 Re...

Page 47: ...vehicle Figure 4 5 Page 4 11 or Figure 4 6 Page 4 12 REAR FENDER INSTALLATION 1 Reverse removal procedure Tighten bolts 2 to 35 in lb 4 0 N m TRAILER HITCH OPTIONAL ON SOME MODELS TRAILER HITCH REMOV...

Page 48: ...Remove hitch 7 from vehicle TRAILER HITCH INSTALLATION 1 Reverse removal procedures to install hitch 14 Figure 4 5 Page 4 11 Tighten hardware to 15 ft lb 20 3 N m Figure 4 6 Rear Fender and Tail Skirt...

Page 49: ...nge under the dash 4 Lift the mat from the vehicle FRONT FLOOR MAT INSTALLATION 1 Install the floor mat in the reverse order of removal 2 Install the brake and accelerator pedals See Section 5 Acceler...

Page 50: ...4...

Page 51: ...TEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR ENGINE OR EXHAUST SYSTEMS FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS USE INSULATED TOOLS WHEN WO...

Page 52: ...stop bumper 22 up or down Figure 5 2 Page 5 3 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard...

Page 53: ...wl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 5 Page 5 4 The gap should be consistent through range of pawl movement If the gap is not consistent loosen the four b...

Page 54: ...joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 5 8 Page 5 5 3 7 If the accelerator push rod was disconnected from the accelerator...

Page 55: ...proceed to step 5 Adjust Accelerator Rod Gasoline Vehicles For electric Turf 1 and Carryall 1 vehicles proceed to step 5 Adjust Accelerator Rod Turf 1 and Carryall 1 Electric Vehicle Only For electri...

Page 56: ...g events occur in the exact order shown TO PREVENT ACCIDENTALLY STARTING THE VEHICLE DISCONNECT THE BATTERY IES AS INSTRUCTED IN WARNING ON PAGES 5 1 AND 5 2 THIS WILL PREVENT THE POSSIBILITY OF THE V...

Page 57: ...ccelerator rod then the wiper switch arm is exerting excessive pressure against the housing proceed to step 5 3 If the accelerator rod can be easily connected it is correctly adjusted 5 3 If accelerat...

Page 58: ...ht should be 4 5 8 inches 11 7 cm Use a rubber strap to hold the pedal in depressed position and proceed to step 6 3 Figure 5 16 Page 5 11 AN ADAPTER PLUG ASSEMBLY CLUB CAR PART NO 1018945 01 IS AVAIL...

Page 59: ...f Carryall Vehicle Maintenance and Service Manual Page 5 9 5 Figure 5 14 Accelerator Pedal Electric Turf 1 Carryall 1 and all Gasoline Vehicles OFF ON TYPICAL 4 PLACES TYPICAL 4 PLACES 7 22 21 21 19 1...

Page 60: ...Turf Carryall Vehicle Maintenance and Service Manual 5 Figure 5 15 Accelerator Pedal Turf 2 Carryall 2 and 6 Electric Vehicles OFF ON OFF ON 2 GO 20 TYPICAL 4 PLACES 18 18 25 19 4 5 1 13 12 11 10 7 8...

Page 61: ...nt repeat step 6 4 6 6 Meter should indicate 3 38 to 3 42 volts If not proceed to step 6 7 If so proceed to step 6 9 6 7 Loosen the potentiometer adjustment lock nut Figure 5 19 Page 5 12 6 8 Using a...

Page 62: ...tructed in WARNING on pages 5 1 and 5 2 2 Place chocks under rear wheels and lift front end of vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle fram...

Page 63: ...les the equalizer rod is secured to the left driver side channel on the brake pedal weldment For Turf 2 and Carryall 2 vehicles with four wheel brakes and Carryall 2 Plus vehicles there are two equali...

Page 64: ...push on retainer nut 32 disconnect the torsion spring 22 Figure 5 26 Page 5 17 and slide the pedal off of the shaft See preceding NOTE 3 3 Inspect all parts for wear or damage and replace as necessar...

Page 65: ...pedal assembly weldment 10 Figure 5 26 Page 5 17 Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown Figure 5 27 Page 5 17 Figure 5 23 Brake an...

Page 66: ...ce and Service Manual 5 Figure 5 24 Brake and Park Brake Pedal Assembly and Mounting Four Wheel Brake Vehicles 26 TYPICAL 2 PLACES 36 37 14 TYPICAL 4 PLACES 25 24 21 20 18 19 17 12 TYPICAL 4 PLACES TY...

Page 67: ...NG 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle o...

Page 68: ...ivot rod supports 21 Figure 5 14 Page 5 9 11 Remove the accelerator pedal 1 from the vehicle Figure 5 14 Page 5 9 ACCELERATOR PEDAL INSTALLATION Electric Turf 1 Carryall 1 and all Gasoline Vehicles 1...

Page 69: ...ed counterclockwise slightly to align the splines 9 Move the pivot rod back toward the driver side of the vehicle and line up the scribed match marks on the pivot rod and ratchet Rotate the pivot rod...

Page 70: ...Electric Vehicles 1 Position the accelerator pivot rod support 21 and the potentiometer assembly 26 on the vehicle frame and install the four hex head cap screws 22 flat washers 19 and lock nuts 18 T...

Page 71: ...ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclock...

Page 72: ...1 to the pivot rod Figure 5 15 Page 5 10 and tighten to 50 in lb 5 7 N m See preceding NOTE 15 Install the hex head cap screw 8 and lock nut 18 that attach the actuator lever to the pivot rod Fig ure...

Page 73: ...CLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMA...

Page 74: ...overed in this manual are equipped with two wheel self adjusting brakes two wheel manually adjusted brakes or four wheel manually adjusted brakes See Section 2 Specifications Figure 6 1 Self Adjusting...

Page 75: ...t may be necessary to remove sealant material around the head of each pin 4 2 Insert a 1 2 x 5 8 inch cold chisel under the head of each pin and shear them off as illustrated Fig ure 6 4 Page 6 4 This...

Page 76: ...Remove the adjuster wheel 1 with two washers 2 and 3 from the backing plate Figure 6 7 Page 6 5 BRAKE ASSEMBLY CLEANING SELF ADJUSTING BRAKES Read WARNING on page 6 1 1 Carefully clean the brake backi...

Page 77: ...t of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 10 Page 6 5 See preceding WARN...

Page 78: ...hoe THE TRAILING SHOE HAS 17T STAMPED INTO THE TIP OF THE SHOE FLANGE FIGURE 6 12 PAGE 6 6 THE LEADING SHOE IS STAMPED 17L WHEN INSTALLING THE SHOES THE STAMPINGS ON BOTH SHOES SHOULD BE ORIENTED TO T...

Page 79: ...ting blocks as shown Figure 6 16 Page 6 7 6 Place a flat blade screwdriver under the adjusting arm and raise arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stop...

Page 80: ...plate and all mechanical components See WARNING on page 6 1 2 Remove rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate slide 1 and slide plate 2 with dry moly lubricant Club...

Page 81: ...2 Carryall 2 2 Plus and 6 Vehicles 1 Position one shoe in the slots in the mounting block and brake actuator Figure 6 22 Page 6 10 See following WARNING APPLY GREASE CAREFULLY WHEN PERFORMING THE FOLL...

Page 82: ...ED J10 INSERTED INTO THE MOUNTING BLOCK SLOTS RATHER THAN INTO THE BRAKE ACTUATOR SLOTS FIGURE 6 22 PAGE 6 10 INCORRECTLY INSTALLED BRAKE SHOES WILL BE TOO TIGHT AND MAKE ADJUSTMENT OF THE BRAKE IMPOS...

Page 83: ...equalizer rods 2 and 3 to provide slack in the brake cables and equalizer assemblies Figure 6 28 Page 6 16 Detail B 4 Remove rubber dust cover 4 to uncover brake adjustment bolt 5 on the left rear bra...

Page 84: ...er tighten the lug nuts 12 Lower the vehicle and finish tightening the lug nuts using a crisscross pattern to 55 ft lb 74 58 N m FRONT BRAKE CABLE ADJUSTMENT MANUALLY ADJUSTED BRAKES Read WARNING on p...

Page 85: ...er rod 2 in place with a wrench and tighten the jam nut 1 until it is secured against the equalizer Figure 6 28 Page 6 16 Detail B 11 Install rubber dust covers over brake adjustment bolts 12 Carefull...

Page 86: ...age 6 14 2000 Turf Carryall Vehicle Maintenance and Service Manual 6 Figure 6 26 Rear Manually Adjusted Brake Assembly 13 22 17 11 21 10 11 1 20 TYPICAL 2 PLACES TYPICAL 2 PLACES 16 9 19 10 TYPICAL 4...

Page 87: ...00 Turf Carryall Vehicle Maintenance and Service Manual Page 6 15 6 Figure 6 27 Front Manually Adjusted Brake Assembly 20 10 19 21 23 9 22 11 10 11 16 17 14 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 1 TY...

Page 88: ...y Use new cotter pins when installing brake cables 2 Be sure bolts 20 and new cone locknuts 19 are used to mount the brake assembly Figure 6 26 Page 6 14 or Figure 6 1 Page 6 2 3 Tighten bolts to 30 f...

Page 89: ...cable Figure 6 27 Page 6 15 6 Remove dust cap 6 on hub and bearing assembly Figure 6 29 Page 6 17 7 Remove cotter pin 5 and hex nut 7 from spindle shaft Figure 6 29 Page 6 17 8 Remove hub and bearing...

Page 90: ...indle Figure 6 30 Page 6 18 3 Remove cotter pin 9 clevis pin 10 and E clip 8 from brake cable at equalizer 18 Figure 6 31 Page 6 19 4 Remove bolt 4 and nut 6 from brake cable clamp 5 Figure 6 30 Page...

Page 91: ...d all Turf 6 and Carryall 6 vehicles route cable through hole in I beam crossmember 5 Route brake cable between the shock support 8 and brake cable guide bracket 7 Figure 6 30 Page 6 18 Secure brake c...

Page 92: ...gers for installation of cables Pull cables out of vehicle INSTALLATION 1 Place the cables ends in the equalizer 4 Figure 6 32 Page 6 20 Route cables through hangers in the same manner as the ones rem...

Page 93: ...LE AT A TIME BEFORE LIFTING LOCK THE BRAKES UNLOAD THE CARGO BED AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LB 454 KG MIN...

Page 94: ...base plate contacts the bottom of the steering wheel where it attaches to the steering column Figure 7 2 Page 7 2 4 4 Using a 1 2 inch drive air impact wrench tighten the anvil screw 6 until the steer...

Page 95: ...ash inward while pulling the top of the panel out and down 3 5 Disconnect the wires from the electrical components mounted on the dash panel Do not allow wires to touch 3 6 Slide center dash panel up...

Page 96: ...her 3 from the universal joint Figure 7 4 Page 7 4 6 Remove the nuts 9 bolts 8 and 10 and washers 7 and 11 from the steering column mount 4 and 5 Figure 7 4 Page 7 4 7 Remove the steering column from...

Page 97: ...2 Press the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool Club Car Part No 1014264 or a metal tube approximately six inches 15 2 cm long with a maximum ou...

Page 98: ...the frame using bolts 8 washers 7 and nuts 9 Figure 7 4 Page 7 4 Thread the nuts onto the bolts but do not tighten them 4 Reinstall washer 11 and screw 10 Tighten to 20 ft lb 27 N m Figure 7 4 Page 7...

Page 99: ...b 28 4 N m Figure 7 12 Page 7 10 4 Straighten wheels and then turn steering wheel from lock to lock Wheels should turn smoothly and easily If steering wheel does not turn smoothly and easily inspect s...

Page 100: ...7 8 2 Remove the drag link 28 Figure 7 12 Page 7 10 3 Remove both bellows clamps 2 plastic wire ties Figure 7 12 Page 7 10 4 Remove the hex nut 29 and slide off the dust seal bellows 1 Figure 7 12 Pag...

Page 101: ...3 is excessively worn remove the ball joint and tab washer 4 from the rack by securing the rack in a vise Figure 7 11 Page 7 9 Using wood blocks between the rack and the jaws of the vise to protect t...

Page 102: ...ress on a new bearing exerting all pressure on the inner race grease the bearing before installing it Then install the external snap ring 10 Figure 7 12 Page 7 10 Figure 7 12 Steering Gear IN STEP 4 D...

Page 103: ...7 10 8 Using a socket to apply pressure evenly press in a new dust seal Figure 7 13 Page 7 11 9 Apply a small amount of grease to the rack guide 13 where it comes into contact with the rack 17 Figure...

Page 104: ...ng Adjustment on page 7 7 RACK AND PINION INSTALLATION 1 Position the steering gear box assembly on the shock and gear support and install the bolts 30 wash ers 31 and nuts 32 Do not tighten the mount...

Page 105: ...ads to full thread depth Figure 7 12 Page 7 10 5 Install the ball joint 23 on the spindle arm riser 33 then install the retaining nut and a new cotter pin Figure 7 12 Page 7 10 Tighten nut to 18 ft lb...

Page 106: ...7 17 Page 7 15 Toe in Adjustment 1 On a level surface roll the vehicle forward then stop Make sure the front wheels are pointed straight ahead Do not turn the steering wheel again during this procedur...

Page 107: ...s tube of the vehicle frame and lower the vehicle onto the jack stands 2 Remove both front wheels Figure 7 16 Check Camber Figure 7 17 Adjust Camber Figure 7 18 Check Toe In Figure 7 19 Adjust Toe In...

Page 108: ...18 Tighten to 23 ft lb 31 N m 4 Install the wheels and finger tighten the lug nuts 5 Lower the vehicle and finish tightening lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 6 Adjust camber a...

Page 109: ...f Carryall Vehicle Maintenance and Service Manual Page 7 17 7 Figure 7 21 Two Wheel Brake Vehicle Upper Portion 1 5 2 2 2 2 2 4 4 24 5 23 15 3 2 14 10 5 17 16 6 7 10 8 9 18 12 13 11 TYPICAL 4 PLACES 9...

Page 110: ...ryall Vehicle Maintenance and Service Manual 7 Figure 7 22 Two Wheel Brake Vehicle Lower Portion 15 17 18 19 3 16 14 1 11 21 TYPICAL 4 PLACES TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY 22 2...

Page 111: ...and Drag Link Installation page 7 13 7 For vehicles with four wheel brakes proceed to step 7 8 For vehicles with two wheel brakes proceed to step 8 9 Connect the front brake cables on four wheel brake...

Page 112: ...urf Carryall Vehicle Maintenance and Service Manual 7 Figure 7 23 Four Wheel Brake Vehicle Upper Portion 17 TYPICAL 4 PLACES 20 21 TYPICAL 3 PLACES 1 2 2 2 2 4 4 15 3 2 REFERENCE STEERING GEAR 2 10 5...

Page 113: ...ce and Service Manual Page 7 21 7 Figure 7 24 Four Wheel Brake Lower Portion REFERENCE STEERING GEAR ASSEMBLY PASSENGER SIDE ONLY 15 17 18 19 3 14 1 DRIVER SIDE ONLY 11 21 TYPICAL 4 PLACES 22 24 12 10...

Page 114: ...ter pin position If the hub does not turn freely loosen spindle nut one more cotter pin position 4 Install a new cotter pin 2 If movement continues replace the wheel bearings 5 as required Figure 7 25...

Page 115: ...ub assembly 4 and flat washer 8 on the spindle and start the spindle nut 3 Figure 7 25 Page 7 23 5 Tighten the spindle nut until the hub is hard to turn then back the nut 3 off until the hub turns fre...

Page 116: ...7...

Page 117: ...TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING UNLOAD CARGO BED LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE...

Page 118: ...emove the wheel WHEEL INSTALLATION 1 Install wheel s and tighten the lug nuts using a crisscross pattern until they are snug 2 Lower the vehicle and finish tightening the lug nuts using a crisscross p...

Page 119: ...gure 8 1 Page 8 2 and carefully pry the lower bead over the rim flange 3 4 Once the lower bead is started over the rim flange the tire can be removed from the rim by hand TIRE REPAIR 1 Determine the l...

Page 120: ...nd will help ensure that beads snap into place and form a proper seal as the tire is inflated Figure 8 2 Page 8 4 See following WARNING 7 Quickly remove the air nozzle and install the valve core 8 Adj...

Page 121: ...NSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR ENGINE OR EXHAUST SY...

Page 122: ...gure 9 1 Page 9 2 INSTALLING SHOCK ABSORBERS 1 To install reverse the removal procedure 2 On the upper shock absorber mount tighten nut 5 until rubber bushing 10 expands to size of cup washer 3 On the...

Page 123: ...is will keep the brake drum on the hub 5 Remove lower nut 5 cup washer 9 and rubber bushing 10 from shock absorber 7 Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 6 For vehicles with jounce bumpers 6 1 R...

Page 124: ...Figure 9 3 Rear Suspension Vehicles With Jounce Bumpers ELECTRIC VEHICLES ONLY 1 14 13 19 21 11 TYPICAL ON BOTH SIDES 17 REAR BRAKE CABLE 24 18 TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE TYPICAL 2...

Page 125: ...Maintenance and Service Manual Page 9 5 9 Figure 9 4 Rear Suspension Vehicles Without Jounce Bumpers 4 ELECTRIC VEHICLES ONLY 1 4 3 15 4 3 4 9 10 10 9 7 TYPICAL 2 PLACES 5 14 16 12 3 4 24 18 25 REAR B...

Page 126: ...end of leaf spring with the holes in the spring shackles 1 Insert bolt 15 through leaf spring eye and shackles Install locknut 2 and tighten to 15 ft lb 20 3 N m Lower transaxle onto leaf spring 12 Fi...

Page 127: ...s 1 to 13 ft lb 17 6 N m Figure 9 5 Page 9 7 3 Tighten snubber bracket mounting nuts 1 to 13 ft lb 17 6 N m Figure 9 5 Page 9 7 STABILIZER BAR Read WARNING on page 9 1 A stabilizer bar is installed on...

Page 128: ...le mounting brackets Install a bushing 13 onto bar making sure the bushing is located in the center of the four mounting holes in the bracket Figure 9 6 Page 9 8 2 Place the bushing support 12 onto th...

Page 129: ...bar link mount 8 into the stabilizer bar link 5 and finger tighten 7 Repeat steps 5 and 6 for the other side of the stabilizer bar 8 Tighten bolts 6 in the stabilizer bar links 5 to 17 ft lb 23 N m 9...

Page 130: ...9...

Page 131: ...eaning 6 8 shoe installation 6 9 brakes self adjusting adjustment 6 8 assembly cleaning 6 4 shoe installation 6 6 bumper removal and installation 4 13 C CAUTION definition of 1 1 choke 3 7 cleaning br...

Page 132: ...assembly 7 9 disassembly 7 8 installation 7 12 removal 7 7 reverse buzzer performance inspection 3 2 S safety 1 1 serial number vehicle 3 1 shock absorbers rear 9 2 side door 4 10 snubber 9 7 specific...

Page 133: ...13 tie rod and drag link removal and installation 7 12 tilt bed loading and unloading 3 12 removal and installation 4 5 tires pressure 8 1 tire installation 8 3 tire removal 8 3 tire repair 8 3 towin...

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Page 136: ...Golf Cars and Utility Vehicles Club Car Inc P O Box 204658 Augusta GA 30917 4658...

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