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Unread 10-14-2012, 08:40 PM   #1
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Default The rebuild begins...1992 Club Car DS upgrade

I am currently in the process of bringing my old 1992 Club Car back to life. It was that or buy a newer cart, and I just like to tinker, so I decided to spend some time and money.

I had already changed the electrical system to a 4845 400 amp Alltrax Controller, PB-6 throttle, made my own 4g cables. The cart ran pretty good for the last 3 years. However, it needs to be freshened up, and I will be posting photos, hopefully to help thos BGW members who have older Club Cars and want to rebuild them.

Here are a few photos prior to the start:


I purchased a Jake's 6 inch Double A-arm lift kit and HD rear springs (yes, from one of the site sponsors!). I am very impressed with the quality and fit of the kit. I really had very little problems installing it, other than the rear spring bolts near the batteries, which were corroded and just about welded shut. PB Blaster for a few days, then a 2 foot pry bar attached to the wrench took care of those. I am installing all new Grade 8 hardware everywhere.

The front tie rods were shot. I have already ordered (2) LH and (1) RH threaded tie rods. The Steering Unit appears to be OK, I can't detect any play in it.

Here's my first question> I will be using Monroe 32126 (or equivalent) rear shocks instead of shock extenders on the rear. This seems to be what some of you guys are using with no problems. I need new front shocks, and would like something else besides the standard CC shock. I would also like for all (4) shocks to be of the same brand if possible. I have been looking at the Monroe pdf in the stickys, but the shocks that I find that match compression and expansion lengths end up being different types of shocks.

Please give me some suggestions. Many more photos to follow
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File Type: jpg Club Car 2012 rebuild 019.jpg (143.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 020.jpg (103.9 KB, 0 views)
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Unread 10-15-2012, 12:27 PM   #2
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Default Re: The rebuild begins...1992 Club Car DS upgrade

After looking at the Monroe 32126 shock online, I see that it is not the correct mounting type for a 1992 Club Car. I am still searching for the correct front and rear automotive shock replacements!

The front shocks are eyelet mounted. Compressed length is 8 1/4 inches and Extended length is 10 1/4 inches.

The rear shocks are stud mounted at both top and bottom. With the lift kit, I would need a Compressed length of around 11-14 inches and an Extended length of 17 inches or greater. The Monroe shock that might work would be 31125 or 32262.

I will be taking both shocks to Autozone today, to see if I can find some kind of a match.
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Unread 10-16-2012, 07:04 AM   #3
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Default Re: The rebuild begins...1992 Club Car DS upgrade

. . . look into Monroe 5758 shocks . . . I have used them before on another cart where rear stock shocks were too short . . .
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Unread 10-16-2012, 08:59 AM   #4
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Stevegrmich, thanks for the reply. Did you use the 5758 Monroe shocks as a direct replacement of the rear shocks, with shock extenders? A check of the pdf file shows the correct style mount on both ends (S4), with a compressed length of 9.375 inches and an extended length of 14.625. With my lift kit installed. the shock extended length must be at least 17.00 inches. So, I don't think that they are long enough to use without shock extenders.

I managed to cross reference a set of Gabriel shocks with Monroe part number 31125. The Gabriel part number is 82125. These have a compressed length of 12.250 inches and an extended length of 20.750 inches. I am waiting for them to arrive!

I finally gave up trying to find any automotive shocks for the front. I just ordered new front CC shocks.

More photos to follow!
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Unread 10-16-2012, 09:09 AM   #5
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Quote:
Originally Posted by Xact1 View Post
Stevegrmich, thanks for the reply. Did you use the 5758 Monroe shocks as a direct replacement of the rear shocks, with shock extenders?

More photos to follow!

I used the Monroe 5758 shocks (62 T-Bird) when I put non CC heavy duty springs on a 99 CC DS and the stock shocks were way too short . . . no lift kit was installed . . .
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Unread 10-16-2012, 09:18 AM   #6
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Quote:
Originally Posted by Stevegrmich View Post
I used the Monroe 5758 shocks (62 T-Bird) when I put non CC heavy duty springs on a 99 CC DS and the stock shocks were way too short . . . no lift kit was installed . . .

Thanks for clearing this up. The 5758 looks like a good replacement shock for an upgrade without a lift kit.

Hopefully this helps some of the other BGW members out there who are looking for replacement shocks. Also, using the search function can help with finding some good replacement shocks.
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Unread 10-16-2012, 11:22 AM   #7
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Where did you order your tie rods?
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Unread 10-16-2012, 11:43 AM   #8
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Default Re: The rebuild begins...1992 Club Car DS upgrade

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Originally Posted by wildandwonderfulprod View Post
Where did you order your tie rods?
Everything Carts. They have good prices and free shipping over $99.00.

You need (2) LH thread and (1) RH thread for this vintage CC.
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Unread 10-16-2012, 11:45 AM   #9
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Sweet. Thanks! I've got a '93 CC that gets squirrelly at anything over 5mph! Lol
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Unread 10-19-2012, 02:01 PM   #10
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Default Re: The rebuild begins...1992 Club Car DS upgrade

OK, I got the Jake's Double A-arm lift kit installed. It was pretty simple, with only a few problems:

1. One of the replacement tie rods had a stripped nut. BRAND NEW! I couldn't believe it. The old nuts would not work, so I called the vendor for a replacement.

2. I had to open the Jakes's spindle hole a little with a large round file, in order to accept the tie rod. A pain, but not too bad.

3. I spent a lot of time aligning the tires. I wanted the steering wheel centered, with the tires at the proper camber. I may have to tweak just a bit.

4. I had to shave the top rubber bushing for the passenger side rear shock in order for it to fit.

5. I am still waiting for new front shocks. They should arrive next week.

I took the cart out for a ride. Even with the HD rear springs and the Gabriel shocks, the cart rides pretty nice. I like it!

Next up will be the installation of some items that I bought from Scottyb: a HD F/R switch, new cables, and a throttle linkage kit. I had made my own 4 gauge cables, and my own linkage to the PB-6 box, but Scottyb's just look so much better!
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File Type: jpg Club Car 2012 rebuild 003.jpg (251.8 KB, 0 views)
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