Transaxle Assembly - Club Car Electric Precedent 2008 Maintenance And Service Manual

20
Transaxle Disassembly, Inspection, and Assembly

TRANSAXLE ASSEMBLY

CAUTION
• Do not press against the bearing outer race.
• The housing and all parts must be wiped clean and dry before reassembly.
1. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 20-5,
Page 20-3).
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figure 20-5, Page 20-3). Apply a small amount of oil to all thrust plates and to both
ends of the pin.
2.2. Install the hex bolts (33) and output gear (32). Tighten bolts to 58 ft-lb (78.6 N·m).
3. Press a new bearing (18) onto the intermediate gear assembly (Figure 20-5, Page 20-3).
4. Press new bearing (16) onto input pinion gear (17).
5. Apply grease to the lip of the new oil seal (10) and install the seal using a transaxle pinion seal tool (CCI P/N
1014161). The lip of the oil seal should face the inside of the transaxle housing. Make sure the seal is firmly
seated.
6. Install the differential assembly (4), the intermediate gear assembly (3), and the input pinion gear (2)
simultaneously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation (Figure 20-11, Page 20-7).
7. Install dowel pin(s) (25) (if originally installed) in the transaxle housing (20) (Figure 20-5, Page 20-3).
8. Install left half of transaxle housing:
8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing.
8.2. Install left half of transaxle housing (20) (Figure 20-5, Page 20-3).
8.3. Install bolts (24) in the case housing and tighten to 19 ft-lb (25.7 N·m). Type G transaxles have no shims
or gasket.
8.4. Install axle tube (14 and 35) with bolts (8) (Figure 20-5, Page 20-3). Tighten the bolts to 37 ft-lb (50.2 N·m).
9. Install the brake assemblies as instructed. See Brake Cluster Installation on page 6-11.
10. Apply a small amount of grease to the lip of the oil seal (15) (Figure 20-5, Page 20-3). See following CAUTION.
CAUTION
• Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to
installing the axle shaft to prevent oil from coming in contact with brakes.
11. Install the rear axle onto the transaxle.
11.1. Insert the splined end of the axle shaft into the axle tube. Be careful not to damage the seal on the inside of
the axle tube hub. Advance the shaft through to the bearing on the shaft, and rotate it to align the shaft
splines with the splined bore of the differential gear. Continue advancing the shaft until the bearing on the
axle is firmly seated within the axle tube hub seat.
11.2. Using 90° internal snap ring pliers (0.090 tip) (CCI P/N 1012560), attach the internal retaining ring into the
axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside
wall of the axle tube hub (Figure 20-5, Page 20-3).
11.3. Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four or five
locations to ensure it is properly seated. See following WARNING.
Page 20-10 2008 Electric Precedent Maintenance and Service Manual
TRANSAXLE (TYPE G)