Multi-Leaf Springs; Multi-Leaf Spring Removal - Club Car Carryall 500 2015 Maintenance And Service Manual

9

Multi-Leaf Springs

NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter
as the retainers. Do not over tighten.
1. On the upper and lower shock absorber mounting stems, tighten the nut (1) until the rubber bushing (3) expands
to the size of the cup washer (4).
MULTI-LEAF SPRINGS
See General Warnings on page 1-1.

MULTI-LEAF SPRING REMOVAL

1. Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See
Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See Disconnecting the Battery –
Gasoline Vehicles, Section 1, Page 1-4.
2. Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be
removed. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each
rear wheel. Lower the vehicle to let the jack stands support the vehicle (Figure 9-2, Page 9-3). 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. Place a floor jack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just enough
to relieve tension on the shock absorbers without compressing them.
4. Remove the tire and wheel assembly on the side from which the spring is to be removed.
5. Remove the bow-tie pin (1) and the clevis pin (2) at the brake lever and brake cable connection and pull the
clevis (3) away from the lever (Figure 9-3, Page 9-3). Detach the brake cable from the shock mount bracket
(Figure 9-2, Page 9-3).
6. Remove the nut (1), cup washers (4), and rubber bushings (3) from the lower mounting stem of the shock
absorber (Figure 9-4, Page 9-4).
7. Remove the nuts (7) and the U-bolt (9) securing the spring to the shock mounting bracket (16). Remove the
shock mount bracket (6), angle bracket (8), and the U-bolt (Figure 9-4, Page 9-4).
8. Remove the nut (11) and bolt (17) attaching the rear spring to the lower end of the shackle brackets (13).
9. Remove the nut (11) and bolt (17) attaching the front of the spring to the vehicle frame and remove the spring.
10. Inspect the bushings and spacers in the spring eyes and replace them if they are worn or damaged.
Page 9-2 2015 Carryall 500 and 700 Maintenance and Service Manual
REAR SUSPENSION