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STEERING AND FRONT SUSPENSION
KINGPIN AND STEERING SPINDLE REMOVAL
1. Remove the front hub. See Front Wheel Bearings and Hubs on page 7-20.
2. Remove cotter pins (22) and nuts (20), then remove ball joints from the spindles (Figure 7-20,
Page 7-18). Remove drag link ball joint. See also Tie Rod and Drag Link Removal on page 7-13.
3. Remove the nut (17) and lock washer (if present) from the top of the kingpin (26) (Figure 7-21,
Page 7-19).
4. Raise the upper clevis (16) from the kingpin (Figure 7-21, Page 7-19).
5. Remove the thrust washer (19).
6. Slide the spindle off the kingpin (26).
7. Remove the wave washer (20) and inspect it. If the washer is broken or has a wave bottom to wave crest
height dimension of less than 0.040 inch (0.10 cm), it must be replaced.
8. Remove bolt (25) and nut (14) from bottom of kingpin (26) and remove kingpin.
9. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced.
10. Inspect the bushings (3 and 4). If the bushings are worn or damaged, remove them and press in new
ones. See following NOTE.
NOTE: If the bushings are replaced, ream new bushings to 0.750-0.752 (3/4 inch) (19.05-19.10 mm) in
diameter. The reamer should be long enough to ream both bushings from one direction.
KINGPIN AND STEERING SPINDLE INSTALLATION
1. Inspect all parts and replace them as necessary.
2. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-21,
Page 7-19). Tighten the bolt to
3. Install the wave washer (20) on the kingpin.
4. Install the steering spindle on the kingpin. Then install the thrust washer (19), upper plate clevis (16), and
nut (17). If lock washer was present, do not reinstall. Tighten the nut to 40 ft-lb (54.2 N·m) (Figure 7-21,
Page 7-19).
5. Attach the ball joints (6 and 13) to the spindle arm (23), install and tighten the nut (20), and install the cot-
ter pin (22) (Figure 7-20, Page 7-18).
6. Install the drag link ball joint. See Tie Rod and Drag Link Installation on page 7-13.
7. Install front hub and wheel. See Front Hub Installation on page 7-21.
DELTA A-PLATE REMOVAL
1. Loosen lug nuts on both front wheels and raise front 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.
2. Remove wheel.
3. Remove bolts (10 and 24), A-Plate straps (14), and nuts (5) (Figure 7-20, Page 7-18).
4. Remove the lower shock absorber mounting nut (9), then slide the shock absorber free of the Delta A-
Plate.
5. Remove the Delta A-Plate (1).
6. Inspect the bushings (2) and sleeves (3 and 4) in the Delta A-Plate and replace them if necessary.
23
ft-lb (
31
N·m).
2004 DS Golf Car Maintenance and Service Manual
Front Suspension Components
Page 7-17
7
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