Club Car 2009-20011 Electric Precedent Maintenance And Service Manual page 6

SECTION 5 - ACCELERATOR AND BRAKE PEDAL GROUP ............................................................................ 5-1
Pedal Group - Throttle Position Sensor........................................................................................................... 5-1
Pedal Group Removal................................................................................................................................ 5-1
Throttle Position Sensor (TPS) ................................................................................................................... 5-3
Pedal Group Installation ............................................................................................................................. 5-3
Pedal Group - MCOR .................................................................................................................................... 5-3
Pedal Group Removal................................................................................................................................ 5-3
Pedal Group Installation ............................................................................................................................. 5-4
MCOR ...................................................................................................................................................... 5-4
Debris Shields ............................................................................................................................................... 5-5
Accelerator Pedal Removal ............................................................................................................................ 5-6
Accelerator Pedal Installation ......................................................................................................................... 5-6
Brake Pedal Removal .................................................................................................................................... 5-6
Brake Pedal Installation ................................................................................................................................. 5-6
SECTION 6 - WHEEL BRAKE ASSEMBLIES .................................................................................................... 6-1
General Information ....................................................................................................................................... 6-1
Brake Shoe Removal ..................................................................................................................................... 6-1
Brake Assembly Cleaning .............................................................................................................................. 6-5
Brake Shoe Installation .................................................................................................................................. 6-7
Brake Cable Equalizer Adjustment................................................................................................................ 6-10
Brake Cluster Removal and Installation ..........................................................................................................6-11
Brake Cluster Removal .............................................................................................................................6-11
Brake Cluster Installation ..........................................................................................................................6-11
Brake Cable Removal and Installation........................................................................................................... 6-13
Brake Cable Removal .............................................................................................................................. 6-13
Brake Cable Installation ........................................................................................................................... 6-14
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............................................................................................................................................ 7-2
Steering Column Removal.......................................................................................................................... 7-2
Steering Column Installation....................................................................................................................... 7-3
Rack and Pinion ............................................................................................................................................ 7-4
Rack and Pinion Inspection ........................................................................................................................ 7-4
Rack and Pinion Removal .......................................................................................................................... 7-5
Rack and Pinion Disassembly .................................................................................................................... 7-5
Rack and Pinion Assembly ......................................................................................................................... 7-8
Rack and Pinion Installation ....................................................................................................................... 7-9
Front Suspension .........................................................................................................................................7-11
Lubrication ...............................................................................................................................................7-11
Wheel Alignment ......................................................................................................................................7-11
Front Suspension Components..................................................................................................................... 7-13
Tie Rod End Removal .............................................................................................................................. 7-13
Tie Rod Installation .................................................................................................................................. 7-13
Leaf Spring Removal ............................................................................................................................... 7-14
Leaf Spring Installation............................................................................................................................. 7-14
Kingpin and Steering Spindle Removal ..................................................................................................... 7-14
Kingpin and Steering Spindle Installation................................................................................................... 7-14
Control Arm Removal............................................................................................................................... 7-15
Control Arm Installation ............................................................................................................................ 7-15
Shock Absorber Removal......................................................................................................................... 7-15
Shock Absorber Installation ...................................................................................................................... 7-15
Front Wheel Bearings and Hubs ................................................................................................................... 7-18
Front Wheel Free Play Inspection ............................................................................................................. 7-18
Front Hub Removal.................................................................................................................................. 7-18
Hub Installation........................................................................................................................................ 7-18
Page iv 2009-2011 Electric Precedent Maintenance and Service Manual