Brake Adjustment; Brake Cluster Removal And Installation - Club Car DS 2004 Service Manual

6
WHEEL BRAKE ASSEMBLIES
Brake Shoe Installation, Continued:
∆
CAUTION
• Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and
from the oil seal area.
8. Install the brake drum, and make sure that it is properly seated. See following NOTE.
NOTE: If drum installation is difficult, the brake shoes may need to be adjusted vertically in the mounting
slots.
9. After the drum is installed, make sure the axle and drum turn freely and then install the wheel. See Wheel
Installation, Section 8, Page 8-1.

BRAKE ADJUSTMENT

See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1.
1. When cleaning or repair on both wheels is complete, and with the brake cable still loose, lower the vehicle
to the floor.
2. Make the brake shoe and drum adjustment by pressing and releasing the brake pedal repeatedly until
an audible clicking can no longer be heard.
3. Adjust brake pedal free play.
• For gasoline vehicles: See Pedal Group Adjustment – Gasoline Vehicle, Section 5, Page 5-12.
• For electric V-Glide vehicles: See Pedal Group Adjustment – Electric V-Glide Vehicles, Section 5,
Page 5-21.
• For electric MCOR vehicles: See Pedal Group Adjustment – Electric MCOR Vehicles, Section 5,
Page 5-17.

BRAKE CLUSTER REMOVAL AND INSTALLATION

See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1.
Brake Cluster Removal
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 and loosen the lug nuts on the rear wheels. Lift the rear of the vehicle
with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. See Gen-
eral Warning, Section 1, Page 1-1.
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 lug nuts and rear wheels and then the brake drums. See following NOTE.
NOTE: When servicing vehicles with self-adjusting brakes with badly worn brake shoes and when the
drums cannot be removed by normal methods, perform Step 5 of Brake Shoe Removal on
page 6-1, then continue with this procedure.
Although step 5 – Removing the Axle allows easier access to the brake shoes, it is not imperative
to do so in order to remove the brake shoes.
Page 6-8 2004 DS Golf Car Maintenance and Service Manual
Brake Adjustment