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WHEEL BRAKE ASSEMBLIES
5. Remove the axle.
5.1. Using 90° snap ring pliers (CCI P/N 1012560), remove the axle retaining ring (1) (Figure 6-2,
Page 6-2).
5.2. Pull the axle shaft (2) from the axle tube (Figure 6-2, Page 6-2).
6. Remove bow-tie pin (13) and clevis pin (12) from brake cable (Figure 6-4, Page 6-3).
7. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-4,
Page 6-3).
8. Remove brake assembly from transaxle.
BRAKE CLUSTER INSTALLATION
1. Install in reverse order of disassembly. Use new bow-tie pins when installing brake cables. See following
CAUTION.
∆
CAUTION
• Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and
from the oil seal area.
2. Be sure bolts (11) (CCI P/N 1014153) and new lock nuts (10) (CCI P/N 1013924) are used to mount the
brake assembly (Figure 6-4, Page 6-3).
3. Torque bolts to 30 ft-lb (40.6 N·m). See following WARNING.
∆
WARNING
• Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle
assembly will separate from the transaxle and damage the axle assembly and other
components. Loss of control of the vehicle could result in severe personal injury or death.
4. Tighten lug nuts on rear wheels, using crisscross pattern, to 55 ft-lb (74.6 N·m). See Wheel Installation,
Section 8, Page 8-1.
5. Adjust the brakes. See Brake Adjustment on page 6-8.
BRAKE CABLE REMOVAL AND INSTALLATION
See General Warning, Section 1, Page 1-1. See also Warning on Page 6-1.
Brake Cable 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.
3. Release the park brake if engaged and loosen equalizer retaining nuts (1) on equalizer rod (2) to slightly
loosen the brake cables (3) (Figure 6-18, Page 6-10).
2004 DS Golf Car Maintenance and Service Manual
Brake Cable Removal and Installation
6
Page 6-9
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