Park Brake Removal (Gas And Electric Vehicles); Park Brake Installation (Gas And Electric Vehicles) - Club Car Carryall 500 2019 Maintenance And Service Manual

5
Brake Pedal and Park Brake (Gas and Electric Vehicles)

PARK BRAKE REMOVAL (GAS AND ELECTRIC VEHICLES)

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. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place
jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands. See
following WARNING.
WARNING
• Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor
jack) with 1000 lb (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised
position. Use approved jack stands of proper weight capacity to support the vehicle and chock
the wheels that remain on the floor. When not performing a test or service procedure that requires
movement of the wheels, lock the brakes.
3. Remove the park brake assembly.
3.1. To remove the park brake rod and pawl assembly (17 through 20), remove the push nut (19) and disconnect
the ball joint sleeve (21) from the park brake pedal (1) (Figure 5-4, Page 5-4). See following NOTE.
NOTE: New push nuts (19) and (32) must be used when reassembling the park brake.
3.2. To remove the park brake pedal (1), remove the push retainer nut (32), disconnect the torsion spring (22),
and slide the pedal off of the shaft. See preceding NOTE.
3.3. Inspect all parts for wear and damage and replace as necessary.
Figure 5-4 Park Brake Assembly

PARK BRAKE INSTALLATION (GAS AND ELECTRIC VEHICLES)

1. From the bottom side of the floorboard, insert the park brake rod (17) through the brake pedal assembly opening.
Then install the park brake pawl (35) onto the shaft on the brake pedal assembly (10) and also insert the park
brake rod (17) into the park brake pawl (Figure 5-4, Page 5-4).
2. Install the push nut (19) on to the park brake pawl shaft.
3. Install the spacer (23) and torsion spring (22) on the park brake pedal shaft on the brake pedal assembly.
Page 5-4 2019 Carryall 500 and 700 Maintenance and Service Manual
ACCELERATOR AND BRAKE PEDAL GROUP
20
A. Hook one end of spring (20) on park brake weldment.
B. Lift other end of spring (20) up and over brake weldment by prying
down on shaft with small screwdriver.
C. Shaft
Figure 5-5 Torsion Spring Installation
A
C
B