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Unread 06-23-2016, 02:28 PM   #1
Not Yet Wild
 
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Default Guidance needed for Madjax 6" lift install with heavy duty rear springs

So I've been lurking here for a while, reading up, watching YouTube's, etc. and felt like I was prepared for the lift and rear shock install on my ~1996 48V DS. I ran into some issues and have some questions -- any help?

1) I am having problems, even when helped by a friend, with lining up the mounting hole in the top of the axle block and the bottom of the new heavy duty springs. I compared the new springs to the old and they are the exact length but it seems no matter what I do with one side of the axle still attached to the golf cart that I can't get them to line up easily.
- Would it be better to use a second set of jack stands to hold the axle and completely disconnect it from springs/original ubolts/shocks on the cart to get everything to line up?
- I also found out the hard way (and missed it in my prior research) that the driver side brake line is short for the job. A fix I read was to remove the brake line from the mount plate and let it hang. My brake line is very firm in the plate -- is there a way to remove it without damaging the line?

2) I also ordered 3.5" shock extensions in case I needed them with my heavy duty rear shocks. It seems from lining up things, despite the troubles in #1, that the extensions will be needed to get me the length I need to get the shocks lined up with the new mount plates on top of the new springs. I added an extension to the bottom of the shock where it meets the plate and it doesn't look right -- like the rubber bushings would need to be over the larger wrench flats on the extension.
- Are these shock extensions needed with the lift on an electric cart (I keep seeing it said they are needed for gas but can't find something either way for electric)?
- Do the shock extensions get installed from the top?

Thanks in advance. Here are some pictures of the current state of the build. I thought the front was going to be hard and focused on that a lot. The rear has by far been much harder.

Whoops, can't post links to pictures. Here they are in case you add "h" to the beginning of the URL.
ttp://i271.photobucket.com/albums/jj129/PorkChopsMmm/Home/4D16CDE3-CA82-4B74-B8C1-EAD602F26768_zpsk1metjc0.jpg

ttp://i271.photobucket.com/albums/jj129/PorkChopsMmm/Home/F7D7B331-7305-4D4A-86E3-D4619626B9C4_zpsl0ftlpak.jpg
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Unread 06-23-2016, 10:44 PM   #2
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Default

Personally, I'd follow TahoeDawgs way for rerouting the brake lines during the lifting process. There's a sticky at the top of the threads with a step-by-step guide. It's called "Allports Rear Lift Kit insatll My way" It's the best way and takes the tension outa the brake lines. It's not complicated and pretty straight forward...
If I remember correctly when I did my lift install, I did use 2 jack stands and supported the rearend for lining everything up and ease..
You shouldn't need any shock extensions....I didn't use any for mine. Just the supplied blocks and I was in business!

Good luck and keep us posted and don't hesitate to ask if you have any questions!
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Unread 06-24-2016, 12:59 PM   #3
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Thanks for the guidance. I've read that thread through the other thread a couple of times and I am going to give it a shot tonight. I think it assumes you already know how the brakes are configured, which I don't, but I think it gives me enough to figure it out. Thanks again for the help!
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Unread 06-24-2016, 03:32 PM   #4
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Sorry if this isn't what you are asking but. Do you know that there is a front and back on the heavy duty springs.
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Unread 06-24-2016, 03:50 PM   #5
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Quote:
Originally Posted by jjance View Post
Sorry if this isn't what you are asking but. Do you know that there is a front and back on the heavy duty springs.
Yeah, this sounds like it might be part of the problem. If you turn them backwards, the ends of the springs will still line up with the mounting brackets. However, the axle centering studs will try to push the axle too far forward and you won't be able to complete the axle mounting.
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Unread 06-24-2016, 03:52 PM   #6
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

I can double check to see if that is an issue but before I took off the stock springs I held up one of my aftermarket ones too it and got it lined up. That could be an issue, though, so I will double check. My problem is the brake line is too tight and I can't move the axle back far enough. Thanks for the heads up!
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Unread 06-25-2016, 09:30 PM   #7
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Quote:
Originally Posted by PorkChopsMmm View Post
I can double check to see if that is an issue but before I took off the stock springs I held up one of my aftermarket ones too it and got it lined up. That could be an issue, though, so I will double check. My problem is the brake line is too tight and I can't move the axle back far enough. Thanks for the heads up!
You're going to have two options.
1 - go the Tahoe dog route and reroute your lines by switching the orientation of the drum. This requires removing the axle shaft by removing the c clip that keeps the axle in at the bearing. This is NOT a left loosey type job. If you do not know what your doing you are going to struggle getting that clip out.
THAT SAID THIS IS BY FAR THE BEST WAY and it will prevent issues down the road.
2 - you are going to need to route the brake line UNDER a the leaf spring and LOOSEN THE BRAKE LINES A TON to create enough slack. This is if you do not opt for option 1. If you haven't loosened your brake lines, you're fighting up hill.
This should create enough slack to allow you to fit line into bracket and then connect pin to brakes.

You DO NOT need the 3" leaf spring extension mounts. Use the stock.

Lastly: IF you are using a "two bolt" lift where there are only two bolts to secure axle to leafs, there is a way to do it like Tahoe dog and I can tell you how.
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Unread 06-26-2016, 08:25 AM   #8
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

I think everybody has given you all the advise you need but I'll chime in with my 2.

If you do need to remove the brake line club car makes a tool. I figure out Friday that a 13mm line wrench will also work.

I ended up replacing my driver side cable with a passenger cable.
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Unread 06-26-2016, 02:16 PM   #9
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Thanks for the help everyone! I tried using the snap ring pliers to remove the rear axles and couldn't get them removed, so I just unhooked the brake line from the bracket and it gave me enough wiggle room. I also detached the axle from both sides and that allowed me to get the springs and blocks set correctly. It was scary with the axle wanting to fall forward due to the weight of the electric motor. If I feel the need I will purchase a passenger side brake cable.

I've got everything buttoned up now and I am working on the front alignment. I should have spent more time working on this prior to putting the bodywork and front tray on but I didn't know any better. I think I can get all of the adjustments I need with the cowl on. This forum is so helpful!



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Unread 06-26-2016, 05:06 PM   #10
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Default Re: Guidance needed for Madjax 6" lift install with heavy duty rear springs

Wow! That looks great. You will be pleased with the improvement in ride quality.
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