Cushman HAULER 800X Technician's Repair And Service Manual page 168

REAR SUSPENSION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
ing any repair procedure. Never work on a
vehicle that is supported by a jack alone.
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.
Removal
1. Remove the vinyl cap (31), hex nut (30), shock
washer (28) and rubber shock bushing (29) from the
lower end of the shock absorber
2. Remove the vinyl cap (31), hex nut (30), shock
washer (28) and rubber shock bushing (29) from the
upper end of the shock absorber.
3. Compress the shock absorber (27) and remove it from
between the frame mounting bracket and the lower
mounting plate.
Installation
1. Install the shock absorber washer (28) with the
cupped surface facing upward and the rubber shock
absorber bushing (29) on the top stud of the shock
absorber (27).
2. Insert the top stud into the mounting hole on the frame
bracket then compress the shock absorber (27) with
the shock absorber washer (28) cupped surface fac-
ing down and the rubber shock absorber bushing (29)
in place, until the bottom stud can be installed into the
lower mounting plate.
3. Install a rubber shock absorber bushing (29) and
shock absorber washer (28); cupped surface facing
down on the upper shock absorber stud. Install the
hex nut (30). Tighten the nut (30) until the rubber
bushing expands to the same diameter as the shock
absorber washer. Install the vinyl cap (31).
4. Install a rubber shock absorber bushing (29) and
shock absorber washer (28); cupped surface facing
up on the upper shock absorber stud. Install the hex
nut (30). Tighten the nut (30) until the rubber bushing
expands to the same diameter as the shock absorber
washer. Install the vinyl cap (31).
Removal and installation of the shock is the same for
both sides of the vehicle.
Replace any worn or damaged hardware with new as
required.
Rear Leaf Spring
Tool List
Wheel Chocks ............................................................. 4
Jack Stands ................................................................. 4
Page N-2
Floor Jack ....................................................................1
Wrench,1/2" .................................................................1
Insulated Wrench, 9/16"...............................................1
Socket, 1/2"..................................................................1
Socket, 9/16"................................................................1
Socket, deep well 9/16" ...............................................1
Ratchet ........................................................................1
Torque Wrench, ft. lbs ..................................................1
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.
Removal
1. 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 with jack stands under
the axle tubes clear of the U-bolts and leaf spring
mounting plates.
2. Remove the four hex nuts (24) and washers (23) from
the U-bolts (21), remove the U-bolts from the leaf
spring brackets.
3. Place the floor jack under the rear frame of the vehicle
and raise it enough to take pressure from the leaf
spring (1) off of the lower leaf spring plate (22) on the
rear axle. Support the vehicle frame with another set
of jack stands.
4. Remove the hex head bolts (13) and nuts (14) from
the shackle plates (12) at the rear of the frame.
Remove the flanged urethane bushings (11) and spac-
ers (10) as well.
5. Remove the hex head bolt (3) and nut (5) from the for-
ward leaf spring mounting bracket. The leaf spring (1)
can now be removed from the vehicle.
Installation
Spring installation is in the reverse order of disassembly.
1. Install the large flanged bushing (2) in the end forward
end of the leaf spring (1) and place the leaf spring in
the forward mounting bracket.
2. Install the hex head bolt (3), washer (4) and nut 5) to
secure the forward end of the leaf spring in the
bracket.
Qty.
3. Install one set of the smaller flanged urethane bush-
ings (11) and spacer (10) in the rear frame mounting
holes.
Repair and Service Manual
NOTICE