Front Suspension Components; Tapered Leaf Spring Removal; Tapered Leaf Spring Installation - Club Car DS 2004 Service Manual

7
STEERING AND FRONT SUSPENSION
Toe-in Adjustment, Continued:
6. If adjustment is necessary, loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase
or decrease toe-in (Figure 7-19, Page 7-15). See following CAUTION.
CAUTION
• The tie rod has right-hand threads on one end and left-hand threads on the other end. Right-
hand threads are identified by a groove in the tie rod.
7. Tighten nuts (loosened in step 6) to 21 ft-lb (28 N·m) and recheck toe-in.
8. After toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should
be at the center of its travel. There should be equal travel to the left and right. See following NOTE.
NOTE: If the minimum turning radius is not the same for both left and right turns, adjust the steering (see
Steering Adjustment on page 7-6).
If the vehicle is equipped with the permanent towing or deluxe onboard towing option, adjust by
loosening the ball joint hex nut on the tow assembly and rotating the steering arm to achieve
16 -1/2 inches (42 cm) from centerline of right front tire to the closest edge of the hole in towing lug.

FRONT SUSPENSION COMPONENTS

See General Warning, Section 1, Page 1-1.

TAPERED LEAF SPRING REMOVAL

1. Loosen lug nuts on both front wheels and raise front of 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
General Warning, Section 1, Page 1-1.
2. Remove both front wheels.
3. Remove the nuts (14) and bolts (25) from the bottom of each kingpin (26) (Figure 7-21, Page 7-19).
4. Remove the four bolts (30), four nuts (32), four lock washers (31), and bottom spring plate (29).
5. Remove tapered leaf spring (6).
6. Check the condition of the urethane bushings (27) and steel bushings (28). Replace any that are worn
or damaged.

TAPERED LEAF SPRING INSTALLATION

1. Install urethane bushings (27) and steel bushings (28) into leaf spring eyes (Figure 7-21, Page 7-19).
2. Install tapered leaf spring (6), bottom spring plate (29), four bolts (30), four lock washers (31), and four
nuts (32). Using a crisscross pattern sequence, tighten bolts to 23 ft-lb (31 N·m).
3. Install spring in kingpins (26) with bolts (25) and nuts (14). Tighten to 23 ft-lb (31 N·m).
4. Install the wheels and finger-tighten the lug nuts.
5. Lower the vehicle and finish tightening lug nuts (using a crisscross pattern) to 55 ft-lb (74.6 N·m).
6. Adjust camber and toe-in as instructed on page 7-14.
Page 7-16 2004 DS Golf Car Maintenance and Service Manual
Front Suspension Components