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Unread 08-23-2011, 05:40 PM   #1
Not Yet Wild
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Default Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

Had a rear seat and lift kit installed on my 2003 Club Car DS. I believe they left the original springs on... and with four passengers, going off-road... the rear springs bent. :( Honestly, I shouldn't be surprised and I would have pushed back at them leaving the original springs on if I had know what I know now... but "live and learn"...

So... I ordered replacement Heavy Duty Leaf Springs (http://www.ebay.com/itm/250796909840)

How difficult is this going to be to replace them? What are the steps to doing this? How do I get the weight off of the current springs so that they can come off? Won't the axle fall down and be too difficult to attach back? Do the existing shocks present any added complexity? I took a look online and could not find anything out there to provide assistance. The only suggestion I did see was to do one side at a time.

I have a friend who is "handy" and said he could do this... but I'd like some more info from others out there who have done it before so I know if we're going about it the right way, and if there are any tips or tricks that you can share that will save us a headache.

Thanks,
Paul
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Unread 08-23-2011, 09:22 PM   #2
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

Just take your time, its not that hard. Do one side at a time so the axle does not roll over on you and possibly pull the wires off the motor.
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Unread 08-24-2011, 06:47 AM   #3
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

I have done two carts . . the biggest problem you will face is the two mounting bolts towards the front of the cart . . . they will most likely be rusted and seized inside the steel sleeves . . . you can attempt to soak them with PB/Kroil/etc and pound them out or cut them . . . be prepared to replace the bolts . . . I believe they are 3/8", standard thread and 3" long, grade 5 . . . new bolts are not included in the spring kits . . . if buying from dealer, HD springs will not include the rubber bushings or sleeves or bolts . . . after market HD springs usually include the bushings and sleeves . . . it is not a difficult job overall . . . you will need to support the body with jack stands in the rear area under frame and also need to support the axle with a floor jack . . . only take one side apart at a time . . . block all wheels to prevent cart from rolling . . . release parking brake so tension is released on brake cables . . . but most of all, have fun . . . keep six pack in fridge until finished changing springs . . .
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Unread 08-24-2011, 07:54 AM   #4
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

3/8 by 3 1/4" bolts for the leaf springs and they are hard to find at local

hardware. You can find 3 and 3 1/2 but when you say 3 1/4 they look at you

like your crazy. LOL

Anyway 3 1/2 will work just has more sticking out, 3" will not go thru nutt far

enough for teflon to lock. Thought this may help.
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Unread 08-24-2011, 10:11 AM   #5
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

Another thing you may want to consider: the aftermarket HD 4-leaf springs are very stiff - I took them apart and used only two of the four leafs (remove the two smallest ones) and they are OK for four passengers and not too stiff. Follow earlier advice on doing one at a time, is very easy, except for rusted front bolts as indicated in earlier response. Soak them in PB Blaster overnight and it will help.
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Unread 08-24-2011, 01:04 PM   #6
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

just replaced my on a ds cart had to cut the front bolts out also replace the rubber bushings .
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Unread 08-24-2011, 09:21 PM   #7
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

Here's a tip for those front bolts...... Take some PB Blaster NOW and let them start soaking. If you've got pneumatic air tools you should be fine. Put a 9/16" Short socket on the 3/8" Impact wrench and loosen the bolt and remove the nut. Remove your open end wrench and give it hell! Let it spin, spin, spin, and spin some more. This generates SO MUCH heat that the rust will break free 99% of the time and the bolt will tap right out.
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Unread 10-08-2011, 09:39 PM   #8
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

I just put a rear seat and heavy duty springs on my 2006 CC. Like has been said already, the front bolts will definitely be a pain. Air tools are the ticket. definitely use some form of penetrating oil NOW! The only thing that I have run into is the stock shocks aren't long enough. I will now be on the hunt for some longer ones.
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Unread 10-08-2011, 10:30 PM   #9
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

All Good advice Just did a set on a 2000 DS last week ...... take your time and make sure the little centering pin goes in the hole before you try tightening down the U bolts and don't over tighten the U bolts they can be broken off or worse ..... I have seen them break off a week later from being stretched ... I do not know the correct torque spec or I would post it.

Welcome to BGW savage25 ! as you can see by the great responses ~ BGW ROCKS!
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Unread 10-09-2011, 06:41 AM   #10
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Default Re: Installing Club Car DS Golf Cart Rear Heavy Duty Leaf Springs

Quote:
Originally Posted by billyjoeraybob View Post
I just put a rear seat and heavy duty springs on my 2006 CC. Like has been said already, the front bolts will definitely be a pain. Air tools are the ticket. definitely use some form of penetrating oil NOW! The only thing that I have run into is the stock shocks aren't long enough. I will now be on the hunt for some longer ones.
I had same shock issue and wound up replacing them with Monroe 5758 shocks in order to get proper length . . . or you can buy stud extenders for current shocks if they are still in good condition . . .
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