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Strech Plastics 1980-2003 Model Installation Instructions Manual Download Page 22

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STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS

21

ASSEMBLY

STEP 6:

Once it looks 
square place a 
3/8” washer and 
3/8”-16 Nylock 
nut on the front 
bolts. Snug these 
then measure 
again to make 
sure that you are 
still square.

STEP 7:

Making sure that 
you are still square 
you will now use 
the sub frame as a 
template for drill-
ing two 3/8” holes 
into the chasis. 
The holes are the 
two rear most 
holes on the 
sub frame.

Summary of Contents for 1980-2003 Model

Page 1: ...ECK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS INSTALLATION INSTRUCTIONS C 7 06 LONGTRAVEL SUSPENSION FOR CLUB CAR 1980 2003 Model ...

Page 2: ...PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS TABLE OF CONTENTS Progressive Suspension Kit 2 Kit Contents 3 6 Disassembly 7 17 Assembly 18 32 Finishing Touches 33 34 01 ...

Page 3: ...IGHEST QUALITY GOLF CAR PRODUCTS 02 PROGRESSIVE SUSPENSION KIT AA BB CC DD EE ID Qty Product Description AA 2 MS 7 01A Coil Over Dual Rate Shock 16 BB 1 INSTRUCTIONS Washer Usage Instructions CC 4 MS 7 01 1 Shock Sleeves DD 4 MS 7 01 2 Lower Eye Mount Washers EE 1 MS 7 01 3 Spanner Wrench FF 1 MS 7 01 4 Cam Adjuster Lubricant 3 gms FF ...

Page 4: ...US ON THE WEB TO CHECK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 03 KIT CONTENTS A B C D E F G H I J K O L M N ...

Page 5: ...920 Lower A Arm Passenger Side C 1 AFE 925 Lower A Arm Driver Side D 1 AFC 920 Brushguard E 2 C 7 04 4 3 4 Shaft King Pin F 2 AFE 930 Upper J Arm G 1 AFC 960 Steering Shaft H 2 C 7 04 1 3 8 Tie Rod I 1 AFC 950 Pinch Plate J 1 MS 7 19 Passenger Side Spindle K 1 MS 7 18 Driver Side Spindle L 2 MS 7 16 1 2 20 Male Heim Joint M 2 MS 7 24 3 8 24 Male Heim Joint N 1 AFE 411 Universal Joint O 1 AFC 935 R...

Page 6: ...N THE WEB TO CHECK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 05 KIT CONTENTS A B E F H K L M C N O D P G I Q R S J ...

Page 7: ...ut G 16 HW38 47 3 8 Flat Washer USS H 2 HW12 65 1 2 20 SAE Washer Grade 8 I 2 HW38 74 3 8 24 Nylon Insert Lock Nut J 4 HW516 17 5 16 18 Nylon Lock Nut Zinc K 2 HW38 03 3 8 x 16 x 1 1 2 H H C S Garde 2 Zinc L 6 HW38 34 3 8 16 x 3 1 2 H H C S Grade 8 M 2 HW38 35 3 8 16 x 5 Hex Bolt Grade 8 N 4 HW38 41 3 8 16 x 2 Bolts Grade 8 O 4 HW38 42 3 8 16 x 4 1 2 Bolts Grade 8 P 2 HW38 45 3 8 x 16 x 1 1 2 H H ...

Page 8: ...strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 07 DISASSEMBLY STEP 1 Remove top supports STEP 2 Loosen the six pinch screws They are located on the inside around the cowl trim Then lift cowl trim ...

Page 9: ...OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 08 DISASSEMBLY STEP 3 Remove front bumper and cowl fastening rivets STEP 4 Remove front cowl ...

Page 10: ...RE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 09 DISASSEMBLY STEP 5 Raise golf car and place jack stands under frame for support STEP 6 Remove wheels ...

Page 11: ...AT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 10 DISASSEMBLY STEP 7 Locate the wheel hub then remove dust cover STEP 8 Remove cotter pin STEP 9 Remove castle nut ...

Page 12: ...rechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 11 DISASSEMBLY STEP 10 Remove hub then repeat steps 7 10 on other side STEP 11 Remove cotter pins and castle nuts on tie rod ends and steering drag link ...

Page 13: ...ECK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 12 DISASSEMBLY STEP 12 Using a pickle fork remove steering drag link and tie rod end ...

Page 14: ...strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 13 DISASSEMBLY STEP 13 Remove existing spindle and the bolt in top of each shock The spindle is bolted to the front leaf spring and the control arm ...

Page 15: ...CK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 14 DISASSEMBLY STEP 14 Remove control arms Each control arm is attached with two bolts ...

Page 16: ...EB TO CHECK OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 15 DISASSEMBLY STEP 15 Remove leaf spring STEP 16 Remove pinch plate ...

Page 17: ... U joint at lower pinch Make sure to keep this bolt Once you do this the frame that the rack and pinion is mounted to should be able to be removed STEP 18 Remove passenger side glove box This is held on with three rivets and one screw One rivet is located on the top middle The screw is located on the top left side of the glove box and is covered by a plastic cap Simply drill out the three rivets a...

Page 18: ...OUT MORE GREAT PRODUCTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 17 DISASSEMBLY You are now ready to begin with the assembly of the Longtravel Suspension Kit ...

Page 19: ...l bit NOTE THE FIRST FEW STEPS ARE THE MOST IMPORTANT SO PAY ATTENTION IT IS IMPORTANT THAT YOU MAKE SURE THAT THE SUSPENSION KIT SUB FRAME MOUNTS SQUARE ON THE CLUB CAR CHASIS IF YOU IGNORE DOING THIS THEN THE ENTIRE KIT WILL SIT COCKEYED STEP 2 Cut off 1 16 to 1 8 on either side of the front mount ing plate This step may or may not be required You may want to try step three first If you are unab...

Page 20: ...CTS www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 19 ASSEMBLY STEP 3 Place the suspension sub frame on the club car chasis It works best to start at an angle and then straighten out ...

Page 21: ...OLF CAR PRODUCTS 20 ASSEMBLY STEP 4 Place two 3 8 x 1 1 2 grade 8 bolts in the front of the sub frame into the chasis front mount ing plate This will hold the frame in place while you take some measurments STEP 5 Measure from the back of the sub frame to the front of the chasis mounting plate The distance should be equal on the left and the right side ...

Page 22: ...DUCTS 21 ASSEMBLY STEP 6 Once it looks square place a 3 8 washer and 3 8 16 Nylock nut on the front bolts Snug these then measure again to make sure that you are still square STEP 7 Making sure that you are still square you will now use the sub frame as a template for drill ing two 3 8 holes into the chasis The holes are the two rear most holes on the sub frame ...

Page 23: ...e the top hole as your template for drilling a bottom hole It is important to drill straight up and down You will be putting a pinch plate on the bottom holes STEP 9 Place the sub frame back on and make sure you are square again Once you are square place your front bolts back in and tighten Make sure you are still square Then take two 3 8 x 4 1 2 16 grade 8 bolts and place them in the back holes y...

Page 24: ...If every thing was drilled straight you should be able to slip it on over the bolts Then using a 3 8 16 nylock nut and 3 8 washers on each bolt tighten the pinch plate Check for square again STEP 11 Find the middle mounting tabs on the sub frame Then using two 3 8 x 4 1 2 16 grade 8 bolts and 3 8 16 Nylock nuts fasten the frame to the chasis Do not tight en too tight or the I beam may begin to twi...

Page 25: ...e bushings into each of the upper J arms and six into each of the lower A arms STEP 13 Identify the lower A arms Place the two lower A arms on the floor with the shock tab mounts toward the floor Using the picture to the left identify which arm goes where STEP 14 Bolt king pin on A arms Use 3 8 x 3 1 2 16 grade 8 bolt and 3 8 16 Nylock nut and tighten to pinch point on bushings Driver Side Passeng...

Page 26: ...nsert 1 2 20 spindle heims into each of the upper J arms You may need to remove bolts located in upper J arms STEP 16 Attach upper J arms to the sub frame Using a 3 8 x 5 16 grade 8 bolt and 3 8 x16 Nylock nut tighten to pinch point on bushings Make sure that when you attach the J arm that it bends toward the car Also the bolt must be inserted from the front towards the back It is a snug fit so so...

Page 27: ...w strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 26 ASSEMBLY STEP 17 Attach the lower A arms Use two 3 8 x 3 1 2 16 grade 8 bolts and two 3 8 16 Nylock nuts Tighten to a pinch point on bushings ...

Page 28: ...E on J arm heim threads and screw them together be sure to use the 1 2 20 SAE grade 8 washers This step will require some dexterity and some muscle to make them align You will prob ably want to use a pry bar to get it into position NOTE APPLYING LOCTITE ON HEIM THREADS IS A VERY IMPORTANT STEP IF NOT DONE MAY CAUSE SERIOUS DAMAGE OR INJURY STEP 20 Install coil over progres sive shocks The shock at...

Page 29: ...ALITY GOLF CAR PRODUCTS 28 ASSEMBLY STEP 21 Install one 3 8 x 24 jam nut on each of the 3 8 x 24 heims Then attach the two 3 8 x 24 heims to tie rods One heim per tie rod STEP 22 Take the provided rack and pinion unit Clip the two zip ties on outer ends Then remove the heim joints and pop out the heim joint spacer Discard the heim joint spacers ...

Page 30: ...ded 3 8 24 jam nuts and washer on heim joints you just removed Then insert the heim joint back on the rack and pinion If you desire you may also use zip ties on the ends again STEP 24 Place the provided U joint on the rack and pinion Then tighten with provided 8mm pinch bolt STEP 25 Insert the steering column into the top U joint Make sure that the square notch faces the hole where the bolt is ins...

Page 31: ...F CAR PRODUCTS 30 ASSEMBLY STEP 26 Get the two 5 16 x 2 16 grade 8 bolts and have them readily available Take the rack and pinion and place it on the front below the chasis Lift the rack and pinion until steering column is inserted into the U joint Now using the two bolts and two 3 8 16 Nylock nut attach the rack and pinion to the front of the sub frame ...

Page 32: ...BUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS 31 ASSEMBLY STEP 27 Tighten the bolts that attach the rack and pinion to sub frame and in stall an 8mm pinch bolt on the U joint STEP 28 Attach the tie rods to the heim joint on the rack and pin ion using the 3 8 x 1 1 2 16 grade 2 bolts and 3 8 x 16 nuts DO NOT tighten yet ...

Page 33: ...m Place a 3 8 24 Nylon insert lock nut on the end but do not tighten yet STEP 30 Put wheel hub back on Slide the wheel hub onto the spindle Place castle nut on and lock in place with cotter pin Then put dust cover back on Note Inspect bearings repacking may be required STEP 31 Mount your favorite Strech Plastics wheels back onto the car raise it with a jack remove jack stands lower the car to the ...

Page 34: ... Once you have equal play in each direction tighten your jam nuts STEP 1 Align your front wheels To align the wheels measure from the front inside of the tires and then repeat in the back inside of our tires Toe the wheels to your desired width 1 8 toein is recommended To adjust a wheel simply remove the heim in the spindle control arm unscrew the heim from the tie rod and reinsert the heim into t...

Page 35: ...re that bolts with urethene bushings are only tightened to a pinch Before reinstalling the cowl or installing a new cowl make sure the steering feels good and the drive is smooth STEP 4 Reinstall Club Car cowl or install one of Strech Plastics custom Club Car Classic Cowls with Billet Accents After cowl is installed in stall the detachable brush guard using two 5 16 x 1 1 2 16 grade 8 bolts and tw...

Page 36: ...S www strechplastics com STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS Specializing In Dashes Trays Steering Wheel Covers Lift Kits Windshields Dash Trays Lights Cowls Rear Seat Kits Wheels and Tires Steering Wheels Billet Accessories Wheel Covers Storage Covers Weather Enclosures Coolers and Brackets Ball and Club Washers Mirrors Ramps Storage Covers ...

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