Club Car Cafe Express Maintenance And Service Manual page 6

SECTION 5 - Accelerator and Brake Pedal Group ............................................................................................. 5-1
Brake Pedal and Park Brake .......................................................................................................................... 5-1
Brake Pedal Removal (Gas and Electric Vehicles) ....................................................................................... 5-1
Brake Pedal Installation (Gas and Electric Vehicles)..................................................................................... 5-1
Park Brake Removal .................................................................................................................................. 5-4
Park Brake Installation ............................................................................................................................... 5-4
Accelerator Pedal .......................................................................................................................................... 5-5
Accelerator Pedal Removal - Gasoline Vehicles .......................................................................................... 5-5
Accelerator Pedal Installation - Gasoline Vehicles ....................................................................................... 5-6
Pedal Group Adjustment ................................................................................................................................ 5-7
SECTION 6 - Wheel Brake Assemblies ............................................................................................................. 6-1
General Information ....................................................................................................................................... 6-1
Brake Shoe Removal ..................................................................................................................................... 6-1
Brake Assembly Cleaning .............................................................................................................................. 6-3
Brake Shoe Installation .................................................................................................................................. 6-5
Brake Adjustment .......................................................................................................................................... 6-6
Brake Cluster Adjustment........................................................................................................................... 6-6
Brake Cable Equalization ........................................................................................................................... 6-9
Final Brake Cluster Adjustment................................................................................................................. 6-10
Test Drive Vehicle .................................................................................................................................... 6-10
Brake Cluster Removal and Installation ..........................................................................................................6-11
Front Brake Cluster Removal.....................................................................................................................6-11
Front Brake Cluster Installation..................................................................................................................6-11
Rear Brake Cluster Removal .................................................................................................................... 6-13
Rear Brake Cluster Installation ................................................................................................................. 6-13
Front Brake Cables...................................................................................................................................... 6-14
Front Brake Cable Removal ..................................................................................................................... 6-15
Front Brake Cable Installation................................................................................................................... 6-15
Rear Brake Cables ...................................................................................................................................... 6-16
Rear Brake Cable Removal ...................................................................................................................... 6-16
Rear Brake Cable Installation ................................................................................................................... 6-16
SECTION 7 - Steering and Front Suspension .................................................................................................... 7-1
General Information ....................................................................................................................................... 7-1
Steering Wheel.............................................................................................................................................. 7-1
Steering Wheel Removal............................................................................................................................ 7-1
Steering Wheel Installation ......................................................................................................................... 7-2
Steering Column............................................................................................................................................ 7-3
Steering Column Removal.......................................................................................................................... 7-4
Steering Column Disassembly .................................................................................................................... 7-4
Steering Column Assembly ........................................................................................................................ 7-4
Steering Column Installation....................................................................................................................... 7-5
Steering Adjustment ...................................................................................................................................... 7-6
Rack and Pinion ............................................................................................................................................ 7-7
Rack and Pinion Inspection ........................................................................................................................ 7-7
Rack and Pinion Removal - Maintenance-Free Ball Joints ........................................................................... 7-7
Rack and Pinion Disassembly .................................................................................................................... 7-8
Rack and Pinion Assembly ....................................................................................................................... 7-10
Rack and Pinion Installation - Maintenance-Free Ball Joints....................................................................... 7-13
Tie Rod and Drag Link ................................................................................................................................. 7-14
Tie Rod and Drag Link Removal - Maintenance-Free Ball Joints ................................................................ 7-14
Tie Rod and Drag Link Installation - Maintenance-Free Ball Joints.............................................................. 7-14
Front Suspension ........................................................................................................................................ 7-15
Lubrication .............................................................................................................................................. 7-15
Wheel Alignment ..................................................................................................................................... 7-15
Front Suspension Components..................................................................................................................... 7-17
Leaf Spring Removal ............................................................................................................................... 7-17
Leaf Spring Installation............................................................................................................................. 7-17
Kingpin and Steering Spindle Removal - Maintenance-Free Ball Joints....................................................... 7-17
Kingpin and Steering Spindle Installation - Maintenance-Free Ball Joints.................................................... 7-20
Page iv 2018 Café Express Maintenance and Service Manual