Strech Plastics 1980-2003 Model User manual

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INSTALLATION INSTRUCTIONS
C-7-06
LONGTRAVEL
SUSPENSION
FOR CLUB CAR
1980—2003 Model

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TABLE OF CONTENTS
Progressive Suspension Kit............................................... 2
Kit Contents .................................................................3-6
Disassembly ............................................................... 7-17
Assembly .................................................................18-32
Finishing Touches ..................................................... 33-34
01

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02
PROGRESSIVE SUSPENSION KIT
AA
BB
CC DD
EE
ID Qty Product # Description
AA 2 MS-7-01A Coil Over Dual Rate Shock 16”
BB 1 INSTRUCTIONS Washer Usage Instructions
CC 4 MS-7-01-1 Shock Sleeves
DD 4 MS-7-01-2 Lower Eye Mount Washers
EE 1 MS-7-01-3 Spanner Wrench
FF 1 MS-7-01-4 Cam Adjuster Lubricant (3 gms)
FF

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STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS
03
KIT CONTENTS
A
B
C
D
E
F
G
H
I
J
K
O
LM
N

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STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS
ID Qty Product # Description
A 1 AFC-910 Sub Frame
B 1 AFE-920 Lower A-Arm Passenger Side
C 1 AFE-925 Lower A-Arm Driver Side
D 1 AFC-920 Brushguard
E 2 C-7-04-4 3/4” Shaft King Pin
F 2 AFE-930 Upper J Arm
G 1 AFC-960 Steering Shaft
H 2 C-7-04-1 3/8” Tie Rod
I 1 AFC-950 Pinch Plate
J 1 MS-7-19 Passenger Side Spindle
K 1 MS-7-18 Driver Side Spindle
L 2 MS-7-16 1/2”-20 Male Heim Joint
M 2 MS-7-24 3/8”-24 Male Heim Joint
N 1 AFE-411 Universal Joint
O 1 AFC-935 Rack And Pinion Assembly
04

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05
KIT CONTENTS
A
B
E
F
H
K L M
C
N O
D
P
G
I
Q R S
J

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STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS
ID Qty Product # Description
A 16 AFH-210 Urethane Bushing
B 2 HW-138 Round Tubing Plug
C 20 HW38-36 3/8”—16 Nylock Nut/Grade 8
D 4 HW38-43 3/8”—24 Jam Nuts
E 1 HW-23 LOCTITE® Threadlocker
F 2 HW12-64 1/2”—20 Jam Nut
G 16 HW38-47 3/8” Flat Washer USS
H 2 HW12-65 1/2”—20 SAE Washer/Grade 8
I 2 HW38-74 3/8”—24 Nylon Insert Lock Nut
J 4 HW516-17 5/16”—18 Nylon Lock Nut Zinc
K 2 HW38-03 3/8” x 16 x 1-1/2” H.H.C.S./Garde 2 Zinc
L 6 HW38-34 3/8”—16 x 3-1/2” H.H.C.S./Grade 8
M 2 HW38-35 3/8”—16 x 5” Hex Bolt/Grade 8
N 4 HW38-41 3/8”—16 x 2” Bolts/Grade 8
O 4 HW38-42 3/8”—16 x 4-1/2” Bolts/Grade 8
P 2 HW38-45 3/8” x 16 x 1-1/2” H.H.C.S./Grade 8
Q 2 HW516-05 5/16” x 2” H.H.C.S./Grade 2 Zinc
R 2 HW516-52 5/16” x 18 x 2” Bolt/Grade 8
S 2 HW8MM-14 8mm x 1.25 Bolt
06
DO NOT USE PNEUMATIC TOOLS WHEN TIGHTING NUTS & BOLTS

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07
DISASSEMBLY
STEP 1:
Remove top
supports.
STEP 2:
Loosen the six
pinch screws.
They are located
on the inside
around the cowl
trim. Then lift
cowl trim.

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STRECH PLASTICS ARE MANUFACTURERS AND DISTRIBUTORS OF THE HIGHEST QUALITY GOLF CAR PRODUCTS
08
DISASSEMBLY
STEP 3:
Remove front
bumper and
cowl fastening
rivets.
STEP 4:
Remove front
cowl.

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09
DISASSEMBLY
STEP 5:
Raise golf car
and place jack
stands under
frame for
support.
STEP 6:
Remove wheels.

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10
DISASSEMBLY
STEP 7:
Locate the
wheel hub then
remove dust
cover.
STEP 8:
Remove
cotter pin.
STEP 9:
Remove
castle nut.

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11
DISASSEMBLY
STEP 10:
Remove hub
then repeat
steps 7 - 10 on
other side.
STEP 11:
Remove cotter
pins and castle
nuts on tie
rod ends and
steering drag
link.

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12
DISASSEMBLY
STEP 12:
Using a pickle
fork remove
steering drag
link . . .
and tie rod end.

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13
DISASSEMBLY
STEP 13:
Remove existing
spindle, and the
bolt in top of
each shock. The
spindle is bolted
to the front leaf
spring and the
control arm.

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14
DISASSEMBLY
STEP 14:
Remove control
arms. Each control
arm is attached
with two bolts.

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15
DISASSEMBLY
STEP 15:
Remove leaf
spring.
STEP 16:
Remove pinch
plate.

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16
DISASSEMBLY
STEP 17:
Remove rack and
pinion steering
chasis. Loosen
upper U joint at
lower pinch. Make
sure to keep this
bolt. Once you
do this the frame
that the rack and
pinion is mounted
to should be able
to be
removed.
STEP 18:
Remove passenger
side glove box.
This is held on with
three rivets and
one screw. One
rivet is located on
the top middle. The
screw is located on
the top left side of
the glove box and
is covered by a
plastic cap. Simply
drill out the three
rivets and
unscrew the screw
to remove the
glove box.

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17
DISASSEMBLY
You are now ready to begin with the assembly of the Longtravel
Suspension Kit.

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18
ASSEMBLY
STEP 1:
Ream the two
holes on the front
mounting plate.
Use a 1/2” drill bit.
NOTE: THE FIRST FEW STEPS ARE THE MOST IMPORTANT,
SO PAY ATTENTION! IT IS IMPORTANT THAT YOU MAKE
SURE THAT THE SUSPENSION KIT SUB FRAME MOUNTS
SQUARE ON THE CLUB CAR CHASIS. IF YOU IGNORE
DOING THIS THEN THE ENTIRE KIT WILL SIT COCKEYED.
STEP 2:
Cut off 1/16” to
1/8” on either side
of the front mount-
ing plate. This step
may or may not
be required. You
may want to try
step three first. If
you are unable to
accomplish step
three come back to
this step.

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19
ASSEMBLY
STEP 3:
Place the
suspension
sub frame
on the club
car chasis. It
works best
to start at
an angle
and then
straighten out.