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Summary of Contents for Textron EZGO 610987
- Page 1 610987 1 - I N C L U D E S I T E M S 3 - 1 6 SHOP REBUILD AND SERVICE PARTS MANUAL DANA ELECTRIC TRANSAXLE STARTING MODEL YEAR: 2008...
- Page 3 E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855, FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GA 30906-3852 U.S.A.
- Page 4 NOTES Notes: Page ii Dana Electric Transaxle Shop Rebuild and Parts Manual...
- Page 5 INTRODUCTION Read all of each section before attempting any procedure. Pay particular attention to all Warnings, Cautions, and Notes. HOW TO USE THIS MANUAL WARNINGS, CAUTIONS, AND NOTES Throughout this manual, the following WARNINGS, This manual is designed to suit the needs of mechanics CAUTIONS, and NOTES are used.
- Page 6 INTRODUCTION Read all of each section before attempting any procedure. Pay particular attention to all Warnings, Cautions, and Notes. the hot exhaust system. Never work on an engine that is hot. Never work around or operate a vehicle in Before working on vehicle, remove all jewel- an environment that does not ventilate ry (watch, rings, necklaces, etc.).
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Page 7: Table Of Contents
TABLE OF CONTENTS TITLE PAGE Transaxle Disassembly Differential cover Plate Removal ........................A-1 Axle Shaft Assembly Removal........................A-3 Input Gear Assembly Removal ........................A-4 Differential-Carrier Assembly Removal ......................A-5 Intermediate Gear Assembly Removal ......................A-6 Inspection of Parts Oil Seal Inspection............................B-1 Bearing Inspection ............................ - Page 8 TABLE OF CONTENTS Notes: Dana Electric Transaxle Shop Rebuild and Parts Manual...
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Page 9: Transaxle Disassembly
TRANSAXLE DISASSEMBLY TRANSAXLE DISASSEMBLY Tool List Qty. Required Extension, 4", 3/8" drive ..........1 Because some mating parts with wear surfaces were Small diameter pick-up magnet........1 machined together when the transaxle was manufac- tured, or have established wear patterns during Rubber mallet, medium .......... - Page 10 TRANSAXLE DISASSEMBLY 2. Remove ten bolts from differential cover plate. 3. Carefully insert a rigid gasket scraper between the (Ref Fig. A-3 on page A-2) (Ref Fig. A-4 on page cover plate and the differential housing. Pry gently A-2) and remove differential cover plate. Use caution when prying to avoid bending cover plate.
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Page 11: Axle Shaft Assembly Removal
TRANSAXLE DISASSEMBLY Axle Shaft Assembly Removal 2. Remove outer snap ring and axle shaft from driver-side axle tube. The bearing, inner snap ring, 1. Remove outside axle nut, spacer, and hub from and oil seal remain assembled to axle shaft. driver-side axle tube, using a 15/16"... -
Page 12: Input Gear Assembly Removal
TRANSAXLE DISASSEMBLY Input Gear Assembly Removal 3. At axle housing, remove input gear assembly. The input shaft bearing and housing should be a slip- 1. At axle housing, using a seal puller, remove oil fit. Use channel-lock or standard pliers for gripping seal from Input Gear Assembly. -
Page 13: Differential-Carrier Assembly Removal
TRANSAXLE DISASSEMBLY Differential-Carrier Assembly Removal 1. From axle housing, remove four saddle bolts from saddles, then remove saddles. (Ref Fig. A-15 on page A-5) Note the alignment marks on both the housing and saddles. Saddles must be reassembled on the same side from which removed. -
Page 14: Intermediate Gear Assembly Removal
TRANSAXLE DISASSEMBLY Intermediate Gear Assembly Removal 4. Push intermediate gear assembly (1) to narrow side of gear housing and remove bearing (5) from 1. Remove two end cap plugs from axle housing. intermediate gear assembly shaft (4). (Ref Fig. A-18 on page A-6) 5. -
Page 15: Inspection Of Parts
INSPECTION OF PARTS INSPECTION OF PARTS Cover Plate Inspection 1. Perform visual inspection of inside of differential We strongly recommend that all parts found to be damaged be cover plate for contact with gear teeth. Replace as replaced. necessary. Gear Teeth Inspection 1. - Page 16 INSPECTION OF PARTS Notes: Page B-2 Dana Electric Transaxle Shop Rebuild and Parts Manual...
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Page 17: Transaxle Reassembly
TRANSAXLE REASSEMBLY TRANSAXLE REASSEMBLY Tool List Qty. Required Extension, 4", 3/8" drive, ..........1 Ball peen hammer, small..........1 Prior to transaxle reassembly, all parts must be thor- Seal installer ............... 1 oughly cleaned and free of dirt, oil, grease, or resi- Rubber mallet, medium .......... -
Page 18: Intermediate Gear Assembly Installation
TRANSAXLE REASSEMBLY Intermediate Gear Assembly Installation 5. Push intermediate gear assembly (1) toward wide opening of axle housing (2) and install bearing (5) 1. Lubricate two O-rings with 30W motor oil and on intermediate gear assembly shaft (4). (Ref Fig. install them into axle housing. -
Page 19: Differential-Carrier Assembly Installation
TRANSAXLE REASSEMBLY 7. Install two new end cap plugs into axle housing. (Ref Fig. A-5 on page C-3) Fig. A-7 Installing Differential-Carrier into Axle Housing Fig. A-5 End Cap Installed Differential-Carrier Assembly Installation 1. Install drive gear (2) on differential-carrier (3) For accurate torque readings, make sure threads are using four hex head bolts and four locknuts (1). -
Page 20: Input Gear Assembly Installation
TRANSAXLE REASSEMBLY Input Gear Assembly Installation 3. Install retaining ring into the axle housing groove. (Ref Fig. A-11 on page C-4) 1. Lubricate O-ring with 30W motor oil and install into axle housing groove. (Ref Fig. A-9 on page C-4) Fig. -
Page 21: Axle Shaft Installation
TRANSAXLE REASSEMBLY Axle Shaft Installation 3. Tighten outside axle nut to a minimum of 70 lb-ft (95 N•m). Continue to tighten until nut slots are aligned with the hole in the axle shaft. Insert and secure cotter pin. (Ref Fig. A-14 on page C-5) During installation, it may be necessary to tap axle shafts into axle tubes using a hammer handle. -
Page 22: Differential Cover Plate Installation
TRANSAXLE REASSEMBLY Differential Cover Plate Installation Thoroughly inspect housing bolt threads for silicone residue. Failure to properly clean the threads may result in false torque readings and oil leakage. Apply Permatex RTV to differential cover plate prior to installa- Fig. A-16 Differential Cover Plate tion. -
Page 23: Illustrated Parts Breakdown
DANA ELECTRIC TRANSAXLE DANA ELECTRIC TRANSAXLE ILLUSTRATED PARTS BREAKDOWN Page D-1 Dana Electric Transaxle Shop Rebuild and Parts Manual... - Page 24 DANA ELECTRIC TRANSAXLE Electric Vehicle Page D-2 Dana Electric Transaxle Shop Rebuild and Parts Manual...
- Page 25 Electric Vehicle DANA ELECTRIC TRANSAXLE When ordering parts, please specify the model and serial number of the product. E-Z GO ITEM PART NO. DESCRIPTION QTY. MODEL 012AJ408-1 - AXLE ASSEMBLY, REAR (ELECTRIC) 620326 HOUSING, AXLE, SERVICE ................620327 GEAR, INPUT ....................620329 KIT, INPUT GEAR (INCL.
- Page 26 DANA ELECTRIC TRANSAXLE Electric Vehicle When ordering parts, please specify the model and serial number of the product. E-Z GO ITEM PART NO. DESCRIPTION QTY. 620359 RING, RETAINING ..................... 620360 SEALANT, DIFFERENTIAL COVER PLATE ..........620361 KIT, INTERNAL GEARS (INCL. 2, 24, 25) ............620362 KIT, BALL BEARING (INCL.
- Page 28 E-Z-GO DIVISION OF TEXTRON, INC. 1451 MARVIN GRIFFIN RD., AUGUSTA, GA 30906-3852, USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.
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