Ezgo EXPRESS L4 Technician's Repair And Service Manual page 170

REAR SUSPENSION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
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 vinyl cap (31), hex nut (30), shock washer
(28) and rubber shock bushing (29) from the lower end
of the shock absorber
Remove the vinyl cap (31), hex nut (30), shock washer
(28) and rubber shock bushing (29) from the upper end
of the shock absorber.
Compress the shock absorber (27) and remove it from
between the frame mounting bracket and the lower
mounting plate.
Shock Absorber Installation
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).
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 facing
down and the rubber shock absorber bushing (29) in
place, until the bottom stud can be installed into the
lower mounting plate.
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).
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 Removal
Tool List
Wheel Chocks ............................................................. 4
Jack Stands ................................................................. 4
Floor Jack .................................................................... 1
Wrench,1/2" ................................................................. 1
Insulated Wrench, 9/16" .............................................. 1
Page N-2
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.
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.
Remove the four hex nuts (24) and washers (23) from
the U-bolts (21), remove the U-bolts from the leaf spring
brackets.
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.
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 spacers (10) as
well.
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.
Rear Leaf Spring Installation
Spring installation is in the reverse order of disassembly.
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.
Qty.
Install the hex head bolt (3), washer (4) and nut 5) to
secure the forward end of the leaf spring in the bracket.
Install one set of the smaller flanged urethane bushings
(11) and spacer (10) in the rear frame mounting holes.
Repair and Service Manual
NOTICE