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SECTION 6 – WHEEL BRAKE ASSEMBLIES
∆
DANGER
• See General Warning, Section 1, Page 1-1.
∆
WARNING
• See General Warning, Section 1, Page 1-1.
• Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when
these brake mechanisms are handled. Wear approved eye and respiratory protection when
disassembling and cleaning brake mechanisms. Inhalation of asbestos could result in severe
personal injury or death. Do not use compressed air or aerosol sprays to clean the brake
mechanism. Clean brake mechanism using the negative pressure enclosure/hepa vacuum
system or low pressure/wet cleaning method per OSHA/29 CFR - 1910.1001.
GENERAL INFORMATION
DS Golf Cars are equipped with self-adjusting, mechanically-expanding shoe drum brakes on each rear
wheel.
BRAKE SHOE REMOVAL
See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1.
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-2.
2. Place chocks at the front wheels. Loosen, but do not remove lug nuts on rear wheels and lift the rear of
the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle.
3. Loosen the equalizer retaining nuts (2 and 3) on the equalizer rod (1) to loosen the brake cable
(Figure 6-1, Page 6-2).
4. Remove the rear wheels and then the brake drums. If the brake drums were easily removed, proceed to
step 6. 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 severely worn brake shoes and when the drums cannot be removed
by normal methods, proceed to step 5 to minimize damage to the brake cluster and brake compo-
nents.
5. Remove brake drums and badly worn brake shoes.
5.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It
may be necessary to remove sealant material around the head of each pin.
2004 DS Golf Car Maintenance and Service Manual
6
Page 6-1
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