Brake Pedal Installation - Club Car DS 2004 Service Manual

5
ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal Removal, Continued:
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. See following WARNING.
∆
WARNING
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
3. Remove the brake pedal assembly.
3.1. Disconnect the equalizer rod (13) from the pedal shaft by removing the clevis pin (14) and bow-tie
pin (15) (Figure 5-4, Page 5-3).
3.2. Remove the nuts (5), washers (2), bolts (4) and mounting blocks (23). If the mounting blocks show
signs of excessive wear or are damaged, they must be replaced with new ones before installing
pedal assembly.
3.3. Remove the nut (12) and brake stop bumper (11).
3.4. Lift the pedal assembly (8) through the floorboard.

BRAKE PEDAL INSTALLATION

1. From the top side of the floorboard, insert the brake pedal assembly through the opening in the floor as
shown (Figure 5-3, Page 5-2), and install the brake pedal stop bumper (11) on the brake pedal assembly
(Figure 5-4, Page 5-3). Do not tighten the jam nut (12) at this time.
Figure 5-3 Brake Pedal Weldment Through Floor
Page 5-2 2004 DS Golf Car Maintenance and Service Manual
Brake Pedal and Park Brake