Rear Body Installation - Club Car DS 2004 Service Manual

BODY AND TRIM
• Gasoline vehicles:
NOTE: To remove the rear body, the choke button assembly does not have to be removed from the body.
However, adjustment of the choke positioner may be necessary after the rear body is reinstalled.
8.3. Remove four screws and nylon lock nuts securing the Forward/Reverse shifter to the rear body. Pull
the Forward/Reverse shifter (with wiring and cable assembly still connected) from body and allow
it to rest on vehicle frame I-beam.
8.4. Remove the shifter cable from the cable hanger under the driver-side seat hinge.
8.5. Remove two nylon lock nuts from fuel pump and remove fuel pump from seat support.
9. Remove the two screws securing the rear access panel.
10. Remove two carriage bolts (2), nuts (4), and washers (3) attaching the rear legs (1) of the seat back sup-
port assembly to the body (Figure 4-8, Page 4-9).
11. Remove four screws (8), flat washers (9), and spacers (10), attaching the front legs (5) of the seat back
support assembly to the body (Figure 4-8, Page 4-9).
12. Lift seat back assembly from vehicle. (Figure 4-8, Page 4-9).
13. Lift the rear body from the vehicle.
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REAR BODY INSTALLATION

1. Install in reverse order of removal:
1.1. Tighten four screws (8), flat washers (9) and spacers (10), attaching the front legs (5) of the seat
back support assembly to the body to 20 in-lb (2.3 N·m) (Figure 4-8, Page 4-9).
1.2. Tighten the two bolts (2), nuts (4) and washers (3), attaching the rear legs (1) of the seat back sup-
port assembly to the body to 11 ft-lb (14.9 N·m) (Figure 4-8, Page 4-9).
1.3. Tighten screws and lock nuts securing the Forward/Reverse switch or shifter to 33 in-lb (2.8 N·m).
1.4. All vehicles except IQ System vehicles: Install Forward/Reverse handle and tighten to 14 in-lb
(1.6 N·m).
1.5. Tighten kick-plate screws, nuts and washers to 48 in-lb (5.4 N·m) (Figure 4-4, Page 4-7).
1.6. Tighten two screws (1), lock nuts and washers under rear body to 33 in-lb (2.8 N·m) (Figure 4-3,
Page 4-7).
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Figure 4-8 Seat Back Support Front and Rear Leg Mounting
2004 DS Golf Car Maintenance and Service Manual
Rear Body
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Page 4-9
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