Front Suspension And Steering - Cushman HAULER 800X Technician's Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
FRONT 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.
To prevent possible injury or death, follow the
lifting procedure in Section B of this manual.
Place wheel chocks in front and behind the
rear wheels. Check the stability of the vehicle
on the jack stands before starting any repair
procedure. NEVER work on a vehicle that is
supported by a jack alone.
Front Shock Absorber Replacement
Tool List
Wrench, 9/16".............................................................. 1
Remove the nut (4) from the bottom of the shock
absorber (1) at the front axle (2) (Ref Fig. 1). Compress
the shock absorber to clear the mounting bracket.
Loosen the nut (4) securing the top of the shock
absorber to the vehicle frame and then rotate the shock
absorber while holding the nut in place with a wrench.
Remove the shock absorber.
The installation of the shock absorber is the reverse of
disassembly, except that the mounting nuts should be
tightened until the rubber bushings (5) expand to the
diameter of the shock absorber washers (6).
Shock Boot Removal and Replacement
Tool List
Wrench, 9/16".............................................................. 1
Remove the nut (4) from the bottom of the shock
absorber (1) at the front axle (2) (Ref Fig. 1). Compress
the shock absorber to clear the mounting bracket.
Remove clamps securing the boot to the shock absorber
and slide boot down and off the shock absorber.
Replace shock boot and reattach shock absorber as
instructed above.

FRONT SUSPENSION AND STEERING

Front Axle Replacement
Tool List
Wheel chocks ..............................................................4
Floor jack .....................................................................1
Jack stands..................................................................2
Impact wrench .............................................................1
Impact socket, 3/4" ......................................................1
Pliers............................................................................1
Wrench, 3/4" ................................................................1
Plastic faced hammer ..................................................1
Socket, 9/16" ...............................................................1
Wrench, 9/16" ..............................................................1
Torque wrench ft. lbs....................................................1
Lift and support front of vehicle per SAFETY section.
Remove the front wheels. Remove the bottom shock
absorber mounting hardware (Ref Fig. 1).
Loosen the nut (9) until the threaded end of king pin (8)
Qty.
is protected. Tap the nut with a plastic faced hammer to
loosen the king pin.
Remove the nut (9) and washer (23) from the king pin.
Remove the king pin (8), washer (21), thrust washer (10)
and spindle sleeve (22) from the spindle and swing it to
the side. Remove the hardware (12) that secures the
front of the leaf spring to the front axle.
Front axle installation is in the reverse order of disas-
sembly.
The thrust washer is located on top of the spindle bushing.
ITEM
Qty.
9
After replacing the front axle, the axle must be aligned with the
frame. This is not a wheel alignment. Replacing the axle will
also require that the front wheels be aligned.
When the front axle is replaced, it must be aligned to the
frame. The distance from the center bolt at rear of left
spring to the center bolt at front of right spring must be
the same as the distance from the center bolt at rear of
right spring to the center bolt at front of left spring (Ref
Fig. 2).
Repair and Service Manual
NOTICE
TORQUE SPECIFICATION
40 - 45 ft. lbs (54 - 61 Nm)
NOTICE
B
B
Qty.
Page E-1