Shifter Fork Assembly; Differential Gear Case Assembly - Club Car TURF 272 Maintenance Manual

MC010C-BS00 UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK
11. Install the narrow bearing (47), wide bearing (46), and input gear (45) onto the shaft. The smooth collar
of the input gear should be oriented toward the synchronizer ring as shown (Figure 16b-50,
Page 16b-23). The gear should seat inside the ring.
12. Install thrust plate (44) onto the shaft, and the dowel pin (53) into the shaft as shown.
13. Install the spur (governor drive) gear (43) onto the shaft with either side down. Mate the notch in the gear
with the dowel pin as shown.
14. Install the spring washer (42) onto shaft with the raised center toward the end of the shaft.
15. Press a new bearing (41) onto the end of the shaft until it seats (Figure 16b-50, Page 16b-23). Make
sure the input gears turn freely. See following CAUTION.
∆
CAUTION
• Apply pressure against the inner race of the bearing only. Applying pressure anywhere else
will damage the bearing.

SHIFTER FORK ASSEMBLY

1. Install the spring (38) and ball (39) into the shifter fork (37) as shown (Figure 16b-50, Page 16b-23).
2. Use a no. 1 tip phillips screwdriver to depress the ball and spring while inserting shift rod (36) into the
shifter fork (37). Remove screwdriver when the shift rod is inserted far enough for it to depress the ball
and spring, then continue to insert rod until the ball is positioned in the middle detent on the rod
(Figure 16b-50, Page 16b-23).

DIFFERENTIAL GEAR CASE ASSEMBLY

1. If the bearings (70 or 71) were removed, press new ones onto the differential gear carrier case (75) and
carrier case cover (78) (Figure 16b-50, Page 16b-23). See following CAUTION.
∆
CAUTION
• Apply pressure against the inner race of the bearing only. Applying pressure anywhere else
will damage the bearing.
2. Install differential gear (82) into carrier case (75) (Figure 16b-50, Page 16b-23) as shown
(Figure 16b-69, Page 16b-32).
3. Start the differential pin (79) into the carrier case by lightly tapping it in with a plastic or rubber hammer.
Before the pin enters the inside of the carrier case, position the thrust plate (76) and idler gear (80) in the
case and continue tapping the pin through the thrust plate and idler gear as shown (Figure 16b-70,
Page 16b-32).
4. Position the other thrust plate (76) and idler gear (80) in the carrier case. Continue to drive the pin (79)
through them and the wall of the carrier case until the ends of the pin are flush with the sides of the carrier
case (Figure 16b-71, Page 16b-32).
5. Install the thrust plate (77) and differential gear (81) into the carrier case cover (78) (Figure 16b-50,
Page 16b-23) as shown (Figure 16b-72, Page 16b-32). While holding the thrust plate and differential
gear in place, position the carrier case cover on the carrier case.
6. Position the output ring gear (73) (Figure 16b-50, Page 16b-23) on the carrier case, visually aligning the
dowel hole in the carrier case with the dowel pin in the ring gear. Using a plastic or rubber mallet, tap the
ring gear into place on the dowel pin as shown (Figure 16b-73, Page 16b-33).
7. Apply Loctite 277 on the threads of the eight mounting bolts and install them through the ring gear, carrier
case, and into the carrier case cover. Tighten the bolts to 18 ft-lb (24.4 N·m) in the sequence shown
(Figure 16b-74, Page 16b-33).
2001/2002 Turf/Carryall 272 Gasoline Vehicle Maintenance and Service Manual
16B
Component Assembly
Page 16b-31