Front Suspension Components; Leaf Spring Removal; Leaf Spring Installation; Kingpin And Steering Spindle Removal - Maintenance-Free Ball Joints - Club Car Carryall 500 2019 Maintenance And Service Manual

STEERING AND FRONT SUSPENSION

FRONT SUSPENSION COMPONENTS

See General Warnings on page 1-1.

LEAF SPRING REMOVAL

1. Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See
Disconnect the Batteries – Electric Vehicles, Section 1, Page 1-5.
See Disconnect the Battery- Gasoline Vehicles on page 1-4.
2. Remove both front wheels. See Wheel Removal, Section 8, Page 8-1.
3. Remove the nuts (14) and bolts (25) from the bottom of each king pin (26) (Figure 7-19, Page 7-19).
4. Remove the four bolts (30), four nuts (32), four lock washers (31), and bottom spring plate (29).
5. Remove leaf spring (6).
6. Check the condition of the urethane bushings (27) and steel sleeves (28). Replace any that are worn or damaged.

LEAF SPRING INSTALLATION

1. Install urethane bushings (27) and steel sleeves (28) into leaf spring eyes (Figure 7-19, Page 7-19).
2. Install tapered leaf spring (6), bottom spring plate (29), four bolts (30), four lock washers (31), and four nuts (32).
Using a crisscross pattern sequence, tighten bolts to 23 ft·lb (31 N·m).
3. Install spring in king pins (26) with bolts (25) and nuts (14). Tighten to 17 ft·lb (23 N·m).
4. Install the wheels and lower the vehicle. See Wheel Installation, Section 8, Page 8-1.
5. Adjust camber and toe-in. See Camber Adjustment on page 7-15 and Toe-in Adjustment on page 7-16.
KINGPIN AND STEERING SPINDLE REMOVAL – MAINTENANCE-FREE BALL JOINTS
1. Remove the front hub. See Front Hub and Wheel Bearings Removal on page 7-21.
2. Remove nuts (20) and remove ball joints from spindles (Figure 7-18, Page 7-18). Remove drag link ball joint.
See also Tie Rod and Drag Link Removal – Maintenance-Free Ball Joints on page 7-14.
3. Remove the lock nut (17) and conical washer (34) from the top of the kingpin (26) (Figure 7-19, Page 7-19).
4. Raise the upper clevis (16) from the kingpin.
5. Remove the flat washer (33) and thrust washer (19).
6. Slide the spindle (1 or 2) off the kingpin (26).
7. Remove the wave washer (35) and inspect it. If the washer is broken or has a wave bottom to wave crest height
dimension of less than 0.040 inch (0.10 cm), it must be replaced.
8. Remove bolt (25) and nut (14) from bottom of kingpin (26) and remove kingpin.
9. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced.
10. Inspect the bushings (3 and 4). If the bushings are worn or damaged, remove them and press in new ones.
See following NOTE.
NOTE: If the bushings are replaced, ream new bushings from 0.750 inch to 0.752 inch (19.05 to 19.10 mm) in
diameter. The reamer should be long enough to ream both bushings from one direction.
2019 Carryall 500 and 700 Maintenance and Service Manual
Front Suspension Components
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