Leaf Spring Removal; Leaf Spring Installation; Kingpin And Steering Spindle Removal; Kingpin And Steering Spindle Installation - Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

7
Front Suspension Components

LEAF SPRING REMOVAL

1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-3.
2. Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack. Place jack stands
under the aluminum rails of the vehicle frame just aft of the front suspension. Lower the vehicle onto the jack
stands. See General Warnings on page 1-1.
3. Remove both front wheels.
4. Remove the bolts (8) from the bottom of each kingpin (7) (Figure 7-20, Page 7-17).
5. Remove the four bolts (17) and bottom spring plate (16).
6. Remove leaf spring (13).
7. Check the condition of the urethane bushings (15) and steel sleeves (14). Replace any that are worn or damaged.

LEAF SPRING INSTALLATION

1. Install urethane bushings (15) and steel sleeves (14) into leaf spring eyes (Figure 7-20, Page 7-17).
2. Install leaf spring (13), bottom spring plate (16), and four bolts (17). Using a crisscross pattern sequence,
tighten bolts to 37 ft-lb (50 N·m).
3. Install spring in kingpins (7) with bolts (8). Tighten to 30 ft-lb (41 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 and toe-in. See Wheel Alignment on page 7-11.

KINGPIN AND STEERING SPINDLE REMOVAL

1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-3.
2. Remove the front hub. See Front Hub Removal on page 7-18.
3. Remove retaining nuts (14), then remove tie rod ends (12) from the tabs on the spindles (Figure 7-19, Page 7-16).
4. Remove the nut (1) from the top of the kingpin (7) (Figure 7-20, Page 7-17).
5. Raise the upper clevis from the kingpin.
6. Slide the spindle (3) off the kingpin (7).
7. Remove the wave washer (6) and inspect it. If the washer is broken or has a wave bottom to wave crest height
dimension of less than 0.040 inch (1 mm), it must be replaced.
8. Remove bolt (8) from bottom of kingpin (7) and remove kingpin.
9. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced.
10. Inspect the bushings (4). If the bushings are worn or damaged, remove them and press in new ones.

KINGPIN AND STEERING SPINDLE INSTALLATION

1. Inspect all parts and replace them as necessary.
2. Install the kingpin (7) over the leaf spring eye. Insert the bolt (8) (Figure 7-20, Page 7-17). Tighten the bolt to
30 ft-lb (41 N·m).
Page 7-14 2009-2011 Electric Precedent Maintenance and Service Manual
STEERING AND FRONT SUSPENSION