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TransPorter 4
Club Car TransPorter 4 Maintenance Service Manual
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MANUAL NUMBER
1023
976
03
EDITION CODE
1
2
03
B0312A
200
4
MAINTENANCE
SERVICE
MANUAL
VILLAGER 4, VILLAGER 6,
VILLAGER 8, TRANSPORTER 4,
TRANSPORTER 6
GASOLINE/ELECTRIC
TRANSPORTATION VEHICLES
2
Table of Contents
Default Chapter
5
Table of Contents
5
Section 1 - Safety
9
General Warning
9
Section 2 - Vehicle Specifications
13
Section 3 - General Information
17
General Information
17
Serial Number Identification
17
Storage - Gasoline Vehicle
18
Preparing the Gasoline Vehicle for Extended Storage
18
Returning the Stored Gasoline Vehicle to Service
20
Storage - Electric Vehicle
20
Preparing the Electric Vehicle for Extended Storage
21
Returning the Stored Electric Vehicle to Service
21
Section 4 - Body and Trim
23
Cleaning the Vehicle
23
Front Body
24
Center Body - Villager 6 and 8
25
Rear Body - Villager 4, 6, and 8
29
Front and Rear Body Repair
34
Stress Lines or Streaks
34
Minor Impact Damage/Deformations
35
Minor Scratches and Surface Blemishes
35
Small Scratches that Cannot be Buffed out
35
Touch-Up Paint Color Chart
36
Gouges, Punctures, Tears, Large Scratches, and Abrasions
36
Center Body Repair - Villager 6 and 8
36
Flat Bed - Transporter 4
37
Rear Fender - Transporter 4 and 6 ................................................................................................. Tailskirt - Transporter 4 and
38
Floor Mat
39
Bumper
41
Bumper Removal
41
Bumper Installation
41
Section 5 - Accelerator and Brake Pedal Group
43
Brake Pedal and Park Brake
43
Brake Pedal Removal
43
Brake Pedal Installation
46
Park Brake Removal
47
Park Brake Installation
47
Accelerator Pedal - Gasoline Vehicles
48
Accelerator Pedal Removal - Gasoline Vehicles
48
Accelerator Pedal Installation - Gasoline Vehicles
50
Accelerator Pedal - Electric Vehicles
51
Accelerator Pedal Removal - Electric Vehicles
51
Accelerator Pedal Installation - Electric Vehicle
53
Pedal Group Adjustment - Gasoline Vehicles
53
Pedal Group Adjustment - Electric Vehicles
58
Section 6 - Wheel Brake Assemblies
63
General Information
63
Brake Shoe Removal
63
Brake Assembly Cleaning (Self-Adjusting Brakes)
65
Brake Shoe Installation (Self-Adjusting Brakes)
67
Brake Adjustment (Self-Adjusting Brakes)
70
Brake Assembly Cleaning (Manually-Adjusted Brakes)
71
Brake Shoe Installation (Manually-Adjusted Brakes)
72
Brake Adjustment (Manually-Adjusted Brakes)
74
Brake Cluster Adjustment
75
Brake Cable Equalization
78
Final Brake Cluster Adjustment
79
Test Drive Vehicle
79
Brake Cluster Removal and Installation
79
Rear Brake Cluster Removal
79
Rear Brake Cluster Installation
80
Front Brake Cluster Removal
80
Front Brake Cluster Installation
81
Front Brake Cables
82
Front Brake Cable Removal
82
Front Brake Cable Installation
83
Rear Brake Cables
84
Rear Brake Cable Removal
84
Rear Brake Cable Installation
85
Section 7 - Steering and Front Suspension
87
General Information
87
Steering Wheel
87
Steering Wheel Removal
87
Steering Wheel Installation
88
Steering Column
88
Steering Column Removal
88
Steering Column Disassembly
91
Steering Column Assembly
91
Steering Column Installation
91
Steering Adjustment
93
Rack and Pinion
94
Rack and Pinion Removal
94
Rack and Pinion Disassembly
94
Rack and Pinion Assembly
96
Rack and Pinion Installation
98
Tie Rod and Drag Link
99
Tie Rod and Drag Link Removal
99
Tie Rod and Drag Link Installation
99
Front Suspension
100
Lubrication
100
Wheel Alignment
100
Front Suspension Components
102
Leaf Spring Removal
102
Leaf Spring Installation
102
Kingpin and Steering Spindle Removal
103
Kingpin and Steering Spindle Installation
108
Delta A-Plate Removal
108
Delta A-Plate Installation
108
Shock Absorber Removal
108
Shock Absorber Installation
109
Front Wheel Bearings and Hubs (All Except Villager 4)
109
Front Wheel Free Play Inspection
109
Front Wheel Bearings and Hub Removal
110
Front Wheel Bearings and Hub Installation
110
Front Hubs (Villager 4 Vehicles)
111
Front Wheel Free Play Inspection
111
Front Hub Removal
111
Front Hub Installation
111
Section 8 - Wheels and Tires
113
General Information
113
Wheels
113
Wheel Removal
113
Wheel Installation
113
Tires
114
Tire Removal
114
Tire Repair
115
Tire Installation
115
Section 9 - Rear Suspension
117
General Information
117
Shock Absorbers
117
Shock Absorber Inspection and Removal
117
Shock Absorber Installation
118
Multi-Leaf Springs
118
Multi-Leaf Spring Removal
118
Multi-Leaf Spring Installation
119
Snubber
122
Snubber Removal
122
Snubber Installation
122
Stabilizer Bar
123
Stabilizer Bar Removal
123
Stabilizer Bar Installation
124
Jounce Bumpers
124
Jounce Bumper Removal
124
Jounce Bumper Installation
124
Other manuals for Club Car TransPorter 4
Owner's Manual
80 pages
Maintenance And Service Manual
286 pages
4
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Club Car TransPorter 4 Specifications
General
Brand
Club Car
Model
TransPorter 4
Category
Electric Vehicles
Language
English
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