Club Car TURF 272 Maintenance Manual page 493

MC012C-AS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
Unitized Transaxle Assembly, Continued:
8. Make sure the mating surfaces of the left and right sides of the case are clean and free of oil, grease, or
residue of any kind, and they are not scratched or damaged in any way.
9. Apply a continuous bead of Three Bond No. 1215 (CCI P/N 101928701) sealant to the mating surface,
around the complete profile of the right (passenger side) case (Figure 16a-88, Page 16a-38). See fol-
lowing CAUTION.
∆
CAUTION
• Use only Three Bond No. 1215 sealant to seal case. Do not use a substitute.
• If the two sides of the case cannot be easily closed or do not make complete contact, do not
force them together. Check that all internal components are properly seated and then try
again.
10. Install and finger-tighten the fifteen bolts (28) (Figure 16a-40, Page 16a-19) that secure the left and right
sides of the case together. Then, in sequence shown, tighten the bolts to 17 ft-lb (23.1 N·m)
(Figure 16a-89, Page 16a-40).
11. Install the differential lock housing to the transaxle.
11.1. Make sure the mating surfaces of the differential lock housing and the transaxle case are clean and
free of oil, grease or residue of any kind.
11.2. Ensure that the alignment pin is installed to the transaxle case (Figure 16a-90, Page 16a-40).
11.3. Apply a continuous bead of Three Bond No. 1215 (CCI P/N 101928701) around the opening on the
mating surface of the differential lock housing (transaxle side) (Figure 16a-90, Page 16a-40).
11.4. Rotate the differential lock shaft (95) and insert the cog (104) into the differential lock housing (94)
(Figure 16a-74, Page 16a-34).
11.5. Using the alignment pin as a guide, position the differential lock housing onto the driver side of the
transaxle case (Figure 16a-90, Page 16a-40).
12. Install axle tubes (92 and 93) and brake cluster assemblies (if previously removed) on the transaxle case
(Figure 16a-9, Page 16a-8).
12.1. Make sure the mating surfaces of the axle tubes, transaxle case, and differential lock housing are
clean and free of oil, grease, or residue of any kind.
12.2. Apply a continuous bead of Three Bond No. 1215 (CCI P/N 101928701) around the opening on the
(driver) side axle tube as shown (Figure 16a-90, Page 16a-40). Then position the axle tube on the
left side (95) of the transaxle case to the differential lock housing as shown and install eight mount-
ing bolts (Figure 16a-9, Page 16a-8) finger-tight. In the sequence shown, tighten the bolts to 36 ft-
lb (48.8 N·m) (Figure 16a-91, Page 16a-41).
12.3. Install seven mounting bolts (96) on the right (passenger) side axle tube directly to the transaxle
case (Figure 16a-89, Page 16a-40).
12.4. If previously removed, install left and right brake cluster assemblies to the axle tubes. See Brake
Cluster Assembly Replacement, Section 6a, Page 6a-20.
12.5. Install the right (passenger side) axle shaft (91) in the right axle tube (93) (Figure 16a-9,
Page 16a-8). Using 90° angle (0.90 tip) snap ring pliers, install the retaining ring as shown
(Figure 16a-92, Page 16a-41).
12.6. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to
five locations to ensure it is properly seated. See following WARNING.
∆
WARNING
• Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle
assembly will separate from the transaxle and damage the axle assembly and other
components. Loss of vehicle control could result in severe personal injury or death.
2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
Unitized Transaxle Assembly
Page 16a-39
16A