E-Z-GO MPT 800, Technician'S Repair And Service Manual

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FRONT SUSPENSION AND STEERING
Page E-6
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Front Axle Replacement
Tool List Qty. Required
Ratchet, 1/2" drive ....................................................... 1
Socket, 3/4", 1/2" drive ................................................ 1
Wrench, 9/16".............................................................. 1
Wrench, 3/4"................................................................ 1
Plastic faced hammer.................................................. 1
Shop towels.............................................................. AR
Wire .......................................................................... AR
Wrench, 5/8"................................................................ 1
Wrench, 11/16" ............................................................ 1
Socket, 9/16", 1/2" drive .............................................. 1
Socket, 5/8", 1/2" drive ................................................ 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Loosen front wheels. Lift and support front of vehicle per
SAFETY section and remove front wheels.
Remove hardware (1, 4, 5) securing shock absorbers (2)
to front axle (3) (Ref Fig. 6 on page E-5).
On the driver side, remove lock nut (6) and washer (8)
from bolt (7) and discard nut. Pull bolt (7) and washer (9)
from spindle (10) and separate spindle from axle.
Remove thrust washer (11) and king pin tube (12) from
spindle, wrap towel around spindle and let spindle rest
on ground.
Repeat at passenger side letting rack ball joint (29) rest
on front spring to support spindle.
To prevent possible inju-
ry from falling steering
components, secure rack
and pinion unit (16) to front springs with wire. This
will prevent the intermediate shaft connecting the
rack and pinion unit to the steering column from pull-
ing apart due to the weight of the steering system.
The intermediate shaft is assembled with the
universal joints set 90° out of phase with each
other.
Remove hardware (13 - 15) securing rack and pinion unit
(16) to front axle and discard lock nuts (15). Move rack
and pinion unit back to rest on top of front springs (17).
Secure rack and pinion unit to spring with wire to prevent
pulling apart intermediate shaft.
Remove the three 1 3/4" long bolts (18), two 1 1/2" long
bolts (28), spring plate (24) and five lock nuts (19) secur-
ing axle to springs and discard lock nuts. At the 3 1/2"
long bolt (20) securing front of left spring, note location of
washer (22) and remove it from end of bolt. Remove nut
(21), 3 1/2" long bolt (20), spring plate (24) and spacer
(23) and retain them for assembly at their original loca-
tions.
To prevent stress and possible damage
to the rack and pinion unit, the axle
must first be mounted to the springs with the hardware (20 - 23)
installed in its original location (Ref Fig. 6 on page E-5).
To prevent damage to bellows (16), the two 1 1/2" long bolts (28)
must be installed in their original location.
Front axle installation is the reverse order of disassembly
using new lock nuts (15, 19). All hardware (18 - 24, 28)
must be installed in its original location (Ref Fig. 6 on
page E-5).
Tighten leaf spring and rack and pinion unit hardware (13
- 15,18 - 21, 28) to 35 - 50 ft. lbs (50 - 70 Nm) torque.
Install thrust washers (11), king pin tubes (12), spindles,
washers (9) and bolts (7). Tighten new lock nuts (6) to 56
- 70 ft. lbs. (75 - 95 Nm) torque. Check that spindle turns
freely on king pin tube after tightening.
Tighten shock absorber mounting hardware until rubber
bushings expand to diameter of shock absorber washer.
Install front wheels per WHEELS AND TIRES section
and lower vehicle per SAFETY section.
Check front wheel alignment and adjust if necessary.
See ‘Wheel Alignment’ on page E-3.
Axle Linkage Rod Replacement
Raise the front of the vehicle (See Lifting Vehicle).
Remove old axle linkage rod by removing each ball joint
nut (Ref Fig. 7 on page E-7). Check axle alignment (Ref
Fig. 8 on page E-7). Adjust length of new axle linkage rod
until it will pass through and seat in the hole in the front
axle assembly and the rear spring plate without resis-
tance. Tighten the ball joint nuts to 20 - 25 ft. lbs. torque
and rod jam nut to 20 - 25 ft. lbs torque. Lower the vehi-
cle.
Front Spring Replacement
Tool List Qty. Required
Jack stands.................................................................. 4
Ratchet, 1/2" drive .......................................................1
Socket, 3/4", 1/2" drive ................................................ 1
Socket, 5/8", 1/2" drive ................................................ 1
Wrench, 5/8" ................................................................ 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Tape measure.............................................................. 1
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