Shock Absorber Installation; Rear Spring Removal; Rear Spring Installation; Shock Absorber Removal - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers
REAR SUSPENSION
NOTICE
In the following text, there are references to removing/installing
bolts etc. Additional hardware (nuts, washers etc.) that are
removed must always be installed in their original positions
unless otherwise specified. Non specified torque specifications
are as shown in the table contained in Section "A".
General
Tool List
Wheel Chocks ............................................................. 4
Jack Stands ................................................................. 4
Floor Jack.................................................................... 1
Wrench, 1/2"................................................................ 1
Wrench, 9/16".............................................................. 1
Wrench, 3/4"................................................................ 1
Socket, 1/2" ................................................................. 1
Socket, 9/16" ............................................................... 1
Socket, 9/16", Deepwell .............................................. 1
Extension, 3" ............................................................... 1
Ratchet ........................................................................ 1
Torque Wrench, ft. lbs. ................................................ 1
The rear suspension consists of the rear axle and
attachments that secure it to the springs and shock
absorbers (Ref Fig. 1 on page P-2). In addition the rear
axle is secured to the rear of the engine by means of a
casting that is bolted to the engine and mounted to the
rear axle with 'U' bolts. This section is confined to the
removal and replacement of the springs and shock
absorbers. Rear axle shaft removal is covered in REAR
AXLE section.

Shock Absorber Removal

Raise the rear of the vehicle in accordance with the
instructions provided in Section 'B' of this manual and
support the rear of the vehicle on the outer ends of the
rear bumper.
Remove the bottom shock absorber nut (1) (Ref Fig. 1).
Compress the shock absorber (2) and remove the top
shock absorber nut (3).
Remove the shock absorber.

Shock Absorber Installation

Shock absorber installation is in the reverse order of dis-
assembly except that the shock absorber nuts (1,3)
must be tightened until the shock absorber bushings (4)
expand to the diameter of the shock absorber washer
(5).

Rear Spring Removal

To reduce the possibility of personal injury, fol-
Qty
low the lifting procedure in section 'B' of this
manual. Place wheel chocks in front and
behind the front wheels and check the stability
of the vehicle on the jack stands before start-
ing any repair procedure. Never work on a
vehicle that is supported by a jack alone.
If both springs are to be replaced and the rear axle is not to be
removed, it is important to remove and replace one spring at a
time. Springs must be replaced in sets. Never replace just one.
Remove the bottom shock absorber nut (1) (Ref Fig. 1)
Place a floor jack under the center section of the rear
axle (6) and raise just enough to place a second set of
jack stands under the axle tubes. With both the rear axle
and the frame supported, the 'U' bolt (7) and the hard-
ware (8) can be removed.
Remove the rear spring shackle assembly (9) and the
front spring mounting hardware (10).
Remove the spring (11).

Rear Spring Installation

Spring installation is in the reverse order of disassembly.
When installing the rear spring shackles, be sure that the
cupped side of the shackle plate faces the spring.
The shock absorber nuts (1,3) must be tightened until
the shock absorber bushings (4) expand to the diameter
of the shock absorber washer (5) (Ref Fig. 1).
Tighten the front spring hardware (10) to 21 - 25 ft. lbs.
(28 - 34 Nm) torque.
Tighten all other hardware to 18 - 22 ft. lbs. (24 - 30 Nm)
torque.
Repair and Service Manual
REAR SUSPENSION
NOTICE
NOTICE
B
B
Page M-1