Club Car VILLAGER 4 Maintenance Service Manual
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Club Car VILLAGER 4 Maintenance Service Manual

Gasoline/electric transportation vehicles
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2004
MAINTENANCE
SERVICE
MANUAL
VILLAGER 4, VILLAGER 6,
VILLAGER 8, TRANSPORTER 4,
TRANSPORTER 6
GASOLINE/ELECTRIC
TRANSPORTATION VEHICLES
MANUAL NUMBER 102397603
EDITION CODE 1203B0312A

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Summary of Contents for Club Car VILLAGER 4

  • Page 1 2004 MAINTENANCE SERVICE MANUAL VILLAGER 4, VILLAGER 6, VILLAGER 8, TRANSPORTER 4, TRANSPORTER 6 GASOLINE/ELECTRIC TRANSPORTATION VEHICLES MANUAL NUMBER 102397603 EDITION CODE 1203B0312A...
  • Page 3 If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, extension 3580.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    SECTION 4 – BODY AND TRIM Cleaning the Vehicle ......................... Front Body ............................Center Body – Villager 6 and 8 ......................Rear Body – Villager 4, 6, and 8 ....................... Front and Rear Body Repair ......................4-12 Stress Lines or Streaks .........................
  • Page 6 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake ......................Brake Pedal Removal ........................Brake Pedal Installation ....................... Park Brake Removal ........................Park Brake Installation ......................... Accelerator Pedal – Gasoline Vehicles .................... Accelerator Pedal Removal – Gasoline Vehicles ................. Accelerator Pedal Installation –...
  • Page 7 Delta A-Plate Installation ......................7-22 Shock Absorber Removal ......................7-22 Shock Absorber Installation ......................7-23 Front Wheel Bearings and Hubs (All Except Villager 4) ..............7-23 Front Wheel Free Play Inspection ....................7-23 Front Wheel Bearings and Hub Removal ..................7-24 Front Wheel Bearings and Hub Installation ..................
  • Page 8 SECTION 8 – WHEELS AND TIRES General Information ......................... Wheels ............................. Wheel Removal ..........................Wheel Installation ......................... Tires ..............................Tire Removal ..........................Tire Repair ........................... Tire Installation ..........................SECTION 9 – REAR SUSPENSION General Information ......................... Shock Absorbers ..........................Shock Absorber Inspection and Removal ..................Shock Absorber Installation ......................

  • Page 9: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION.
  • Page 10 SAFETY General Warning ∆ WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair.
  • Page 11 Remove negative IN THE TOW POSITION BEFORE battery cables before DISCONNECTING OR cable first. working on vehicle. CONNECTING BATTERY CABLES Figure 1-2 PowerDrive Vehicles Figure 1-3 Villager 4 IQ System Vehicle 2004 Transportation Vehicle Maintenance and Service Manual Page 1-3...

  • Page 13: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS Villager 6 SPECIFICATIONS Villager 4 Transporter 4 Transporter 6 Villager 8 Power- Power- Power- IQ System Pedal-Start Key-Start Drive Key-Start Drive Key-Start Drive POWER SOURCE 48-Volt Gasoline Gasoline System 48 Gasoline System 48 Gasoline System 48...
  • Page 14 VEHICLE SPECIFICATIONS Villager 6 SPECIFICATIONS Villager 4 Transporter 4 Transporter 6 Villager 8 Power- Power- Power- IQ System Pedal-Start Key-Start Drive Key-Start Drive Key-Start Drive BODY/CHASSIS 48-Volt Gasoline Gasoline System 48 Gasoline System 48 Gasoline System 48 Electric Electric Electric...
  • Page 15 VEHICLE SPECIFICATIONS Villager 6 SPECIFICATIONS Villager 4 Transporter 4 Transporter 6 Villager 8 Power- Power- Power- IQ System DIMENSIONS/WEIGHT Pedal-Start Key-Start Drive Key-Start Drive Key-Start Drive 48-Volt (continued) Gasoline Gasoline System 48 Gasoline System 48 Gasoline System 48 Electric Electric...

  • Page 17: Section 3 - General Information

    • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. rec- ommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).

  • Page 18: Storage - Gasoline Vehicle

    GENERAL INFORMATION Storage – Gasoline Vehicle SERIAL NUMBER DECAL SERIAL NUMBER DECAL Club Car SERIAL NUMBER D0401-123456 REAR OF CENTER P O BOX 204658 AUGUSTA GA 30917 DASH VIEWED FROM THE FRONT OF THE VEHICLE (FRONT BODY REMOVED) Club Figure 3-1 Serial Number Decal Figure 3-2 Serial Number Decal Behind Dash STORAGE –...
  • Page 19 GENERAL INFORMATION Storage – Gasoline Vehicle 3. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at 10 amps or less.

  • Page 20: Returning The Stored Gasoline Vehicle To Service

    GENERAL INFORMATION Storage – Electric Vehicle RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1. Connect the battery cables, positive (+) cable first. 2. Restore fuel system to operation. 2.1. Remove plug from the fuel tank vent nipple and connect fuel vent line to nipple. Open the fuel shut- off valve (Figure 3-4, Page 3-4).

  • Page 21: Preparing The Electric Vehicle For Extended Storage

    GENERAL INFORMATION Storage – Electric Vehicle ∆ CAUTION • Batteries in a low state of charge will freeze at low temperatures. • To avoid exposing electrical components to moisture and subsequent damage, do not use any type of pressure washing or steam cleaning equipment to wash the vehicle. PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE 1.

  • Page 23: Section 4 - Body And Trim

    Villager 6 and 8 vehicles are ® equipped with a ABS/DR acrylic center body. Villager 4, 6 and 8 vehicles are equipped with an ArmorFlex rear body. TransPorter 4 and 6 vehicles are manufactured with an aluminum rear body.

  • Page 24: Front Body

    BODY AND TRIM Front Body FRONT BODY See General Warning, Section 1, Page 1-1. Front Body Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 2. For vehicles equipped with headlights, disconnect the headlight wiring harness from the headlight assemblies.

  • Page 25: Center Body - Villager 6 And 8

    BODY AND TRIM Center Body – Villager 6 and 8 Front Body Installation 1. Install front body (8) under trim (9), align holes and finger-tighten screws (16) holding front body against frame (Figure 4-1, Page 4-2). 2. Install carriage bolts (10), washers (11) and lock nuts (17) onto front body trim. Tighten bolts to 11 ft-lb (14.9 N·m).
  • Page 26 BODY AND TRIM Center Body – Villager 6 and 8 Center Body Removal, Continued: 4. Remove the screws (1), lock nuts (3) and washers (2) from each side of the armrest/seat back assembly (6). 5. Remove the armrest/seat back assembly (6) (Figure 4-2, Page 4-3). 6.
  • Page 27 BODY AND TRIM Center Body – Villager 6 and 8 Electric vehicles only: 7. Remove the two bolts (2) and two flat washers (4) that secure the electrical mounting plate to the center body assembly (Figure 4-4, Page 4-4). 8. Remove all wires from the terminal block (1) located on the driver side of the center body assembly. See following NOTE.
  • Page 28 BODY AND TRIM Center Body – Villager 6 and 8 Center Body Installation 1. Install in reverse order of removal. Torque screws (3) and lock nuts (4) to 18 in-lb (2.0 N·m) (Figure 4-3, Page 4-3). 2. Tighten screws (4) to 9 ft-lb (12.2 N·m) and screws (1) to 18 in-lb (2.0 N·m) (Figure 4-2, Page 4-3). 3.

  • Page 29: Rear Body - Villager 4, 6, And 8

    floor mat) (Figure 4-8, Page 4-7). Figure 4-7 Rear Body Figure 4-8 Kick-Plate Screws 7. Villager 4 gasoline vehicles only: Remove the screw securing the Forward/Reverse handle and slide the handle from the shaft. Villager 4 electric vehicles only: NOTE: To remove the rear body, the charger receptacle must be disconnected, but does not have to be removed from the body.
  • Page 30 BODY AND TRIM Rear Body – Villager 4, 6, and 8 Rear Body Removal, Continued: Figure 4-9 IQ System Forward/Reverse Switch Villager 4 Gasoline vehicles only: NOTE: To remove the rear body, the choke button assembly does not have to be removed from the body.
  • Page 31 BODY AND TRIM Rear Body – Villager 4, 6, and 8 TYPICAL 4 PLACES Figure 4-10 Rear Seat/Armrest – Villager 4 2004 Transportation Vehicle Maintenance and Service Manual Page 4-9...
  • Page 32 BODY AND TRIM Rear Body – Villager 4, 6, and 8 Rear Body Removal, Continued: 14.4. Remove the two bolts (26), washers (25) and lock nuts (24) that secure the rear seat (2) and the rear legs of the seat back support (13) to the rear body and lift the rear seat (2) away from the vehi- cle (Figure 4-11, Page 4-10).
  • Page 33 BODY AND TRIM Rear Body – Villager 4, 6, and 8 Villager 6 and 8 gasoline and electric vehicles only: 15. Remove armrest and rear seat: 15.1. Remove screws (22) and washers (23) from each side of the armrest/setback assembly (26) (Figure 4-12, Page 4-11).

  • Page 34: Front And Rear Body Repair

    1.5. Gasoline vehicles only: Install fuel pump. See Section 14 – Fuel System, in the FE290 or FE350 Maintenance and Service Supplement. Villager 4 vehicles only: 1.6. Install rear armrest and tighten screws (3 and 18) and lock nuts (5 and 12) to 65 in-lb (7.35 N·m) (Figure 4-10, Page 4-9).

  • Page 35: Minor Impact Damage/Deformations

    4-14. 3. Use the brush provided with the touch-up paint (available from Club Car Service Parts – see following color chart) to apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 36: Touch-Up Paint Color Chart

    BODY AND TRIM Center Body Repair – Villager 6 and 8 TOUCH-UP PAINT COLOR CHART COLOR CCI P/N Beige 101997201 White 101997202 101997203 Gray 101997204 Dark Gray 101997205 Royal Blue (Pacific Blue) 101997206 Black 101997207 Dark Green 101997209 Classic Blue (Navy) 101997211 Burgundy 101997212...

  • Page 37: Flat Bed - Transporter 4

    BODY AND TRIM Flat Bed – TransPorter 4 FLAT BED – TRANSPORTER 4 See General Warning, Section 1, Page 1-1. NOTE: Flat bed removal and installation will be easier with a helper. Flat Bed Removal 1. Remove the two bolts (16), washers (17) and lock nuts (18) that secure the front of the flat bed to the vehi- cle body (Figure 4-13, Page 4-15).

  • Page 38: Rear Fender - Transporter 4 And 6 ................................................................................................. Tailskirt - Transporter 4 And

    BODY AND TRIM Rear Fender – TransPorter 4 and 6 Flat Bed Removal, Continued: 3. Apply slight upward pressure (by hand) on the rear of the bed to relieve pressure on the hinges and remove the hinge bolts (14) from the hinge assemblies (Figure 4-13, Page 4-15). 4.

  • Page 39: Floor Mat

    3. Install the brake and accelerator pedals. See Section 5 – Accelerator and Brake Pedal Group. 4. Install the horn switch if required. Center and Rear Floor Mat Removal – All Vehicles Except Villager 4 TransPorter 4 and 6 vehicles only: 1.
  • Page 40 BODY AND TRIM Floor Mat TYPICAL 2 PLACES TYPICAL AT EACH FENDER 2 PLACES TYPICAL 2 PLACES AT EACH FENDER TYPICAL TYPICAL 2 PLACES 2 PLACES REAR REVERSE BUZZER Figure 4-14 Rear Fender, Tailskirt and Bumper – TransPorter 4 and 6 Page 4-18 2004 Transportation Vehicle Maintenance and Service Manual...

  • Page 41: Bumper

    BODY AND TRIM Bumper BUMPER See General Warning, Section 1, Page 1-1. BUMPER REMOVAL 1. Remove four lock nuts (10), six flat washers (11), four phillips bolts (12), and mounting plate (9) from rear bumper (8) (Figure 4-14, Page 4-18). 2.

  • Page 43: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. BRAKE PEDAL AND PARK BRAKE See General Warning, Section 1, Page 1-1. BRAKE PEDAL REMOVAL 1.
  • Page 44 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 4 PLACES TYPICAL 2 PLACES VILLAGER 4 ELECTRIC VEHICLES ONLY Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting – Two-Wheel Brake Vehicles Page 5-2 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 45 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake TYPICAL 2 PLACES Figure 5-2 Brake and Park Brake Pedal Assembly and Mounting – Four-Wheel Brake Vehicles 2004 Transportation Vehicle Maintenance and Service Manual Page 5-3...

  • Page 46: Brake Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake Brake Pedal Removal, Continued: 3.3. Remove the nut (25) and brake stop bumper (24) (Figure 5-1, Page 5-2 or Figure 5-2, Page 5-3). 3.4. Lift the pedal assembly (10) through the floorboard (Figure 5-3, Page 5-4). Figure 5-3 Brake Pedal Weldment Through Floor Figure 5-4 Park Brake Assembly BRAKE PEDAL INSTALLATION...

  • Page 47: Park Brake Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake PARK BRAKE REMOVAL 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1. 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 onto the jack stands.

  • Page 48: Accelerator Pedal - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles Park Brake Installation, Continued: Hook one end of spring (20) on park brake weldment. SHAFT Lift other end of spring (20) up and over brake weldment by prying down on shaft with small screwdriver. Figure 5-5 Torsion Spring Installation ACCELERATOR PEDAL –...
  • Page 49 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles 9. Remove the lock nut (26) from the accelerator pivot rod. 10. Press the brake pedal slightly and slide the park brake ratchet (23) toward the end of the accelerator pivot rod.

  • Page 50: Accelerator Pedal Installation - Gasoline Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (19), and lock nuts (18). Finger-tighten nuts at this time (Figure 5-6, Page 5-7).

  • Page 51: Accelerator Pedal - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles ACCELERATOR PEDAL – ELECTRIC VEHICLES See General Warning, Section 1, Page 1-1. ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-1.
  • Page 52 ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles Figure 5-8 Accelerator Pedal – Electric Vehicle Page 5-10 2004 Transportation Vehicle Maintenance and Service Manual...

  • Page 53: Accelerator Pedal Installation - Electric Vehicle

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLE 1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-8, Page 5-10). Finger-tighten nuts at this time.
  • Page 54 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles Pedal Group Adjustment – Gasoline Vehicles, Continued: Figure 5-9 Loosen Rear Brake Equalizer Rod Nuts Figure 5-10 Loosen Front Brake Equalizer Rod Nuts 2.4. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal.
  • Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles CUTAWAY SIDE VIEW 0.060 inch (1.5 mm) BOTTOM VIEW Figure 5-13 Park Brake Ratchet/Pawl Gap Adjustment NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 5 of Pedal Group Adjustment –...
  • Page 56 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 1/2-INCH WRENCH 1/2-INCH SOCKET Figure 5-16 Brake Rod Adjustment Figure 5-17 Accelerator Pedal Height Adjustment 4. Adjust accelerator pedal height. 4.1. Loosen the nut and bolt (Figure 5-17, Page 5-14) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (CCI P/N 101871001) to the accelerator pedal, with the end marked accelerator pedal height closest to the floorboard.
  • Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 5.1. Remove the electrical box screw and cover. See preceding DANGER. 5.2. Loosen the jam nuts (25) and disconnect the accelerator rod (17) at the accelerator pedal (Figure 5-6, Page 5-7). Adjust the length of the rod so the indicated cam edge is parallel with the edge of the electrical component box as shown (Figure 5-19, Page 5-15).

  • Page 58: Pedal Group Adjustment - Electric Vehicles

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Gasoline Vehicles, Continued: NOTE: After the pedal group and accelerator rod are adjusted, the final governed engine RPM should be set. See Engine RPM Adjustment in Section 14 of the appropriate maintenance and service supplement.
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Correct pedal position is 6 inches (15.2 cm) from floormat to back of brake pedal. Figure 5-22 Brake Pedal Height Adjustment Figure 5-23 Brake Pedal Height Measurement 3. Adjust park brake ratchet/pawl gap and pawl engagement. 3.1.
  • Page 60 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles Pedal Group Adjustment – Electric Vehicles, Continued: 3.4. With the park brake locked, make sure at least 75% of ratchet tooth length engages the pawl (Figure 5-26, Page 5-18). Tooth engagement should be between the two lines marked on the pawl. RATCHET (B) TOOTH LENGTH LOCKED POSITION...
  • Page 61 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 4. Adjust accelerator pedal height. 4.1. Loosen the nut and bolt (Figure 5-28, Page 5-18) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (CCI P/N 101871001) to the accelerator pedal, with the end marked accelerator pedal height closest to the floorboard.

  • Page 63: Section 6 - Wheel Brake Assemblies

    OSHA/29 CFR - 1910.1001. GENERAL INFORMATION The Club Car vehicles covered 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. BRAKE SHOE REMOVAL See General Warning, Section 1, Page 1-1.
  • Page 64 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 3. Remove the rear wheels and remove the brake drums. If the brake drums were easily removed, proceed to step 5. See following CAUTION and NOTE. ∆ CAUTION • Worn or damaged brake drums cannot be machined to refinish them. Replace as necessary. NOTE: When servicing vehicles with self-adjusting brakes with badly worn brake shoes and when the drums cannot be removed by normal methods, proceed to step 4 to minimize damage to the brake cluster and brake components.

  • Page 65: Brake Assembly Cleaning (Self-Adjusting Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Self-Adjusting Brakes) Figure 6-4 Rotate Clip Retainer Figure 6-5 Remove Shoes 7. Grasp both brake shoes and pull them, with the springs, out of brake assembly (Figure 6-5, Page 6-3). 8. Self-adjusting brake vehicles only: Remove the adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-6, Page 6-3).
  • Page 66 WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Self-Adjusting Brakes) Brake Assembly Cleaning (Self-Adjusting Brakes), Continued: ∆ WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get on the friction surfaces of the brake shoe pads. Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury.

  • Page 67: Brake Shoe Installation (Self-Adjusting Brakes)

    BRAKE SHOE INSTALLATION (SELF-ADJUSTING BRAKES) See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. Villager 4 vehicles 1. Turn the adjusting wheel screw so the shoe slot is vertical, then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly (Figure 6-12, Page 6-6).
  • Page 68 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) Brake Shoe Installation (Self-Adjusting Brakes), Continued: NOTE: 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 the top of the brake assembly.
  • Page 69 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) 4. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place. Hold shoe in position and install retaining clip (Figure 6-15, Page 6-7). TRAILING LEADING SHOE SHOE...

  • Page 70: Brake Adjustment (Self-Adjusting Brakes)

    BRAKE ADJUSTMENT (SELF-ADJUSTING BRAKES) See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. Villager 4 vehicles 1. When cleaning or repair on both wheels is complete, and with brake cable still loose, lower vehicle to floor.

  • Page 71: Brake Assembly Cleaning (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Manually-Adjusted Brakes) 1/4-INCH TO 1/2-INCH (6.3 TO 12.7 MM) Figure 6-18 Brake Pedal Free Play Adjustment BRAKE ASSEMBLY CLEANING (MANUALLY-ADJUSTED BRAKES) See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. Villager 6, 8, TransPorter 4 and 6 vehicles 1.

  • Page 72: Brake Shoe Installation (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually-Adjusted Brakes) Brake Assembly Cleaning (Manually-Adjusted Brakes), Continued: ∆ WARNING • Apply grease carefully when performing the following steps. Do not allow any grease to get on the friction surfaces of the brake shoe pads. Failure to heed this warning could cause diminished brake performance, possibly resulting in property damage or severe personal injury.
  • Page 73 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually-Adjusted Brakes) 1. Position one shoe in the slots in the mounting block anchor piston and brake actuator (Figure 6-23, Page 6-11). See following WARNING. ∆ WARNING • When installing brake shoes, the shoes must be oriented with tips stamped J10 inserted into the mounting block anchor piston slots rather than into the brake actuator slots (Figure 6-23, Page 6-11).

  • Page 74: Brake Adjustment (Manually-Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Brake Shoe Installation (Manually-Adjusted Brakes), Continued: TIPS Figure 6-25 Insert Shoes Figure 6-26 Position Shoes ∆ CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft.

  • Page 75: Brake Cluster Adjustment

    Figure 6-30 Front Brake Adjustment Bolt 4. Use a torque wrench and a 7-mm 8-point socket or Club Car brake adjustment tool (CCI P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft-lb (20.3 N·m) and continue clockwise rotation to the point at which torque is released.
  • Page 76 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 6-31 Rear Manually-Adjusted Brake Assembly Page 6-14 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 77 WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) Figure 6-32 Front Manually-Adjusted Brake Assembly 2004 Transportation Vehicle Maintenance and Service Manual Page 6-15...

  • Page 78: Brake Cable Equalization

    WHEEL BRAKE ASSEMBLIES Brake Adjustment (Manually-Adjusted Brakes) BRAKE CABLE EQUALIZATION 1. Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-33, Page 6-16).

  • Page 79: Final Brake Cluster Adjustment

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation FINAL BRAKE CLUSTER ADJUSTMENT 1. To adjust the brake shoes, turn the adjustment bolt counterclockwise five clicks. 2. Repeat step 1 at other brake cluster(s). 3. Install the rubber dust covers (4) over the brake adjustment bolts (5) (Figure 6-29, Page 6-13 and Figure 6-30, Page 6-13).

  • Page 80: Rear Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Rear Brake Cluster Removal, Continued: 5. Remove bow-tie pin (17) and clevis pin (16) from brake cable (Figure 6-31, Page 6-14 or Figure 6-11, Page 6-5). 6. Remove 4 bolts (20) and cone lock nuts (19) that mount the brake assembly to the transaxle (Figure 6-31, Page 6-14 or Figure 6-11, Page 6-5).

  • Page 81: Front Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation TYPICAL 4 PLACES Figure 6-34 Front Spindle Assembly (Four-Wheel Brake Vehicles) 7. Remove cotter pin (5) and hex nut (7) from spindle shaft (Figure 6-34, Page 6-19). 8. Remove hub and bearing assembly from spindle shaft. Remove four bolts (22), cone washers (21), lock washers (20) and hex nuts (19) that mount the brake assembly to the spindle (Figure 6-32, Page 6-15).

  • Page 82: Front Brake Cables

    WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLES See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. FRONT BRAKE CABLE REMOVAL 1. Remove bow-tie pin (2) and clevis pin (3) from brake lever arm on front brake cluster (Figure 6-35, Page 6-20).

  • Page 83: Front Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLE INSTALLATION 1. Place brake cable through frame mounting hole behind equalizer and install E-clip (8) on cable housing (Figure 6-36, Page 6-21). FLOORBOARD REMOVED FOR CLARITY TYPICAL 2 PLACES Figure 6-36 Brake Equalizer 2.

  • Page 84: Rear Brake Cables

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables Front Brake Cable Installation, Continued: Figure 6-37 Front Brake Cable Routing REAR BRAKE CABLES See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1. REAR BRAKE CABLE REMOVAL 1. Chock wheels to keep vehicle from unintentionally moving. 2.

  • Page 85: Rear Brake Cable Installation

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables Figure 6-38 Loosen Equalizer Nut Figure 6-39 Disconnect Cables at Rear Brakes REAR BRAKE CABLE INSTALLATION 1. Place the cable ends in the equalizer (4) (Figure 6-38, Page 6-23). Route cables through hangers in the same manner as the ones removed.

  • Page 87: General Information

    SECTION 7 – STEERING AND FRONT SUSPENSION ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.

  • Page 88: Steering Wheel Installation

    STEERING AND FRONT SUSPENSION Steering Column Steering Wheel Removal, Continued: 5.5. Remove the steering wheel puller. 5.6. Remove the steering wheel nut (27) and the steering wheel (25) from the steering column (20) (Figure 7-3, Page 7-3). Figure 7-1 Steering Wheel Puller Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small...
  • Page 89 STEERING AND FRONT SUSPENSION Steering Column TYPICAL 2 VILLAGER 6 AND 8 VEHICLES ONLY PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 7-3 Steering Column 2004 Transportation Vehicle Maintenance and Service Manual Page 7-3...
  • Page 90 STEERING AND FRONT SUSPENSION Steering Column Steering Column Removal, Continued: 3. Remove the center dash panel (Figure 7-4, Page 7-4). 3.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3) (Figure 7-4, Page 7-4). 3.2.

  • Page 91: Steering Column Disassembly

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN DISASSEMBLY 1. Remove bolts (6) and mounts (4 and 5) from steering column. Remove boot (12) (Figure 7-3, Page 7-3). 2. While supporting steering column (20) on a workbench, remove snap ring (13) from shaft. See following NOTE.
  • Page 92 STEERING AND FRONT SUSPENSION Steering Column Steering Column Installation, Continued: 2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to both splined ends of the steering shaft. COLUMN RETAINING TOOL (CCI P/N 1014259) STEP 1 STEP 1 BEARING...

  • Page 93: Steering Adjustment

    STEERING AND FRONT SUSPENSION Steering Adjustment STEERING ADJUSTMENT See General Warning, Section 1, Page 1-1. 1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-7, Page 7-8). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).

  • Page 94: Rack And Pinion

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warning, Section 1, Page 1-1. RACK AND PINION REMOVAL 1. Remove the front body. See Front Body Removal, Section 4, Page 4-2. 2. Remove the cotter pin (22) and ball joint retaining nut (25) (Figure 7-12, Page 7-10). 3.
  • Page 95 STEERING AND FRONT SUSPENSION Rack and Pinion Pry or bump pinion gear PRESS RAM out with universal joint reinstalled. PINION GEAR BEARING Figure 7-9 Remove Pinion from Housing Figure 7-10 Remove Bearing from Pinion 8. If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one.

  • Page 96: Rack And Pinion Assembly

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-11, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
  • Page 97 STEERING AND FRONT SUSPENSION Rack and Pinion CAUTION • In step 4, do not press against the outer race of the bearing. 4. If the bearing (9) was removed, press on a new bearing, exerting all pressure on the inner race (grease the bearing before installing it).

  • Page 98: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: 7. Install the internal snap ring (11) (Figure 7-12, Page 7-10). 8. Using a socket to apply pressure evenly, press in a new dust seal (Figure 7-13, Page 7-11). 9.

  • Page 99: Tie Rod And Drag Link

    STEERING AND FRONT SUSPENSION Tie Rod and Drag Link TIE ROD AND DRAG LINK See General Warning, Section 1, Page 1-1. TIE ROD AND DRAG LINK REMOVAL 1. Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-21, Page 7-18 or Figure 7-23, Page 7-20) and loosen jam nuts (27 and 29) on the drag link (Figure 7-12, Page 7-10).

  • Page 100: Front Suspension

    2. Loosen, but do not remove, the four bolts (30) that secure the leaf spring (6) to the bottom spring plate (29) (Figure 7-22, Page 7-19). See also Figure 7-17, Page 7-14. PROPER Loosen 4 bolts (30). CAMBER Club Car ADJUSTMENT Loosen hex nut (8) on eccentric. ECCENTRIC...
  • Page 101 floor (Figure 7-18, Page 7-15). Club Car Figure 7-18 Check Toe-In Figure 7-19 Adjust Toe-In 4.

  • Page 102: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: CAUTION • The tie rod has right-hand threads on one end and left-hand threads on the other end. Right- hand threads are identified by a groove in the tie rod. 7.

  • Page 103: Kingpin And Steering Spindle Removal

    Front Suspension Components KINGPIN AND STEERING SPINDLE REMOVAL 1. Remove the front hub. See Front Wheel Bearings and Hubs (All Except Villager 4) on page 7-23. • For vehicles with four-wheel brakes, proceed to step 2. • For vehicles with two-wheel brakes, proceed to step 3.
  • Page 104 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-21 Two-Wheel Brake Vehicle – Upper Portion Page 7-18 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 105 STEERING AND FRONT SUSPENSION Front Suspension Components PASSENGER SIDE ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-22 Two-Wheel Brake Vehicle – Lower Portion 2004 Transportation Vehicle Maintenance and Service Manual Page 7-19...
  • Page 106 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-23 Four-Wheel Brake Vehicle – Upper Portion Page 7-20 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 107 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR ASSEMBLY TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY TYPICAL 4 PLACES LEAF SPRING APPEARANCE MAY VARY ON DIFFERENT MODELS. TYPICAL 4 PLACES Figure 7-24 Four-Wheel Brake Vehicle – Lower Portion 2004 Transportation Vehicle Maintenance and Service Manual Page 7-21...

  • Page 108: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components KINGPIN AND STEERING SPINDLE INSTALLATION 1. Inspect all parts and replace them as necessary. 2. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-22, Page 7-19 or Figure 7-24, Page 7-21).

  • Page 109: Shock Absorber Installation

    See General Warning, Section 1, Page 1-1. NOTE: The hubs used on Villager 4 vehicles contain sealed bearings that cannot be serviced or replaced. If the bearings are worn or damaged, the entire hub must be replaced. See Front Hubs (Villager 4 Vehicles) on page 7-25.

  • Page 110: Front Wheel Bearings And Hub Removal

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs (All Except Villager 4) FRONT WHEEL BEARINGS AND HUB REMOVAL 1. Remove the front wheels. See Wheel Removal, Section 8, Page 8-1. 2. Remove the front wheel hubs. 2.1. Remove dust cover (1), cotter pin (2), spindle nut (3), and flat washer (8) (Figure 7-25, Page 7-23).

  • Page 111: Front Hubs (Villager 4 Vehicles)

    STEERING AND FRONT SUSPENSION Front Hubs (Villager 4 Vehicles) FRONT HUBS (VILLAGER 4 VEHICLES) See General Warning, Section 1, Page 1-1. FRONT WHEEL FREE PLAY INSPECTION 1. Raise the front of the vehicle. 2. Using your hands, attempt to rock the wheel and hub assembly back and forth on the spindle. If there is any observable movement of the wheel and hub on the spindle, the hub bearing is worn and the hub assembly must be replaced.

  • Page 113: Section 8 - Wheels And Tires

    - 12-14 psi (0.83-0.96 Bars) for Villager 4 gasoline vehicles - 18-20 psi (1.24-1.38 Bars) for Villager 4 electric vehicles - 30-34 psi (2.07-2.34 Bars) for all other Club Car transportation vehicles • Keep lug nuts properly tightened. • Keep the front end properly aligned and adjusted.

  • Page 114: Tires

    WHEELS AND TIRES Tires TIRES See General Warning, Section 1, Page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. 1. Remove the tire and wheel assembly from the vehicle as instructed. See Wheel Removal on page 8-1. 2.

  • Page 115: Tire Repair

    WHEELS AND TIRES Tires TIRE REPAIR 1. Determine the location and cause of the air leak. 1.1. Remove the wheel as instructed. See Wheel Removal on page 8-1. Inflate the tire to no more than 20 psi (1.38 Bars). 1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air. 1.3.
  • Page 116 • 12-14 psi (0.83-0.96 Bars) for Villager 4 gasoline vehicles • 18-20 psi (1.24-1.38 Bars) for Villager 4 electric vehicles • 30-34 psi (2.07-2.34 Bars) for all other Club Car transportation vehicles 9. Immerse the wheel and tire assembly in water to make sure there are no leaks.

  • Page 117: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION ∆ DANGER • See General Warning, Section 1, Page 1-1. ∆ WARNING • See General Warning, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. The suspen- sion includes two multi-leaf springs controlled by two hydraulic shock absorbers mounted between the spring mounting plate and the frame.

  • Page 118: Shock Absorber Installation

    (10) expands to the same diameter as the cup washer. MULTI-LEAF SPRINGS See General Warning, Section 1, Page 1-1. NOTE: Villager 4 vehicles are equipped with jounce bumpers (Figure 9-3, Page 9-4). MULTI-LEAF SPRING REMOVAL 1. Loosen the lug nuts on the wheel(s) to be removed.

  • Page 119: Multi-Leaf Spring Installation

    6.2. Allow shock mount bracket (16) to rotate downward and remove spring retainer (22). Do not dis- connect brake cable from bracket (Figure 9-3, Page 9-4). 7. For all transportation vehicles except the Villager 4: 7.1. Remove the lock nuts (14) attaching the U-bolt (11) to the shock mount bracket (16). Do not dis- connect brake cable from bracket (Figure 9-4, Page 9-5).
  • Page 120 GAS ONLY TYPICAL ON TYPICAL BOTH SIDES BOTH SIDES OF VEHICLE REAR BRAKE CABLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-3 Rear Suspension – Villager 4 Vehicles Page 9-4 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 121 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-4 Rear Suspension – All Transportation Vehicles Except Villager 4 2004 Transportation Vehicle Maintenance and Service Manual Page 9-5...

  • Page 122: Snubber

    (13) (if present), and lock nuts (14). Tighten U-bolt to 25 ft-lb (34 N·m) (Figure 9-3, Page 9-4). 5. For all transportation vehicles except Villager 4: 5.1. Install shock mount bracket (16) onto locating bolt at bottom center of leaf-spring (Figure 9-4, Page 9-5).

  • Page 123: Stabilizer Bar

    REAR SUSPENSION Stabilizer Bar STABILIZER BAR See General Warning, Section 1, Page 1-1. NOTE: A stabilizer bar is installed on Villager 6, 8, TransPorter 4 and 6 gasoline vehicles only. STABILIZER BAR REMOVAL 1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each rear wheel.

  • Page 124: Stabilizer Bar Installation

    REAR SUSPENSION Jounce Bumpers Stabilizer Bar Removal, Continued: 3. Remove bolts (14) and lock nuts (15) from the left and right stabilizer bar bushing support (12) and remove supports and stabilizer bar (1) from vehicle. 4. Remove bushings (13) from stabilizer bar (1). STABILIZER BAR INSTALLATION 1.
  • Page 125 INDEX pedal height adjustment (electric) ......5-16 accelerator height adjustment (gas) ......5-11 pedal (electric) installation ............. 5-4 height adjustment ........5-19 removal ............5-1 installation ..........5-11 shoe removal ............5-9 installation (manually-adjusted brakes) ..6-10 pedal (gas) installation (self-adjusting brakes) ....6-5 installation ............
  • Page 126 ..............1-1 removal ...........7-24 serial number, vehicle .......... 3-1 front wheel free play inspection .......7-23 shock absorber, front installation ............7-23 front wheel free play inspection (Villager 4 vehicles) 7-25 removal ............7-22 lubrication ............7-14 shock absorber, rear toe-in adjustment ..........7-15 inspection ............
  • Page 127 INDEX tire installation ............8-3 pressure ............8-1 removal ............. 8-2 repair ..............8-3 WARNING definition of ............1-1 wheel see also tire installation ............8-1 removal ............. 8-1 2004 Transportation Vehicle Maintenance and Service Manual Page i-3...
  • Page 129 2004 Transportation Vehicle Maintenance and Service Manual...
  • Page 132 Transportation and Utility Vehicles Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658...

This manual is also suitable for:

Villager 6Villager 8Transporter 4Transporter 6

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