Club Car Gasoline Service Manual page 295

Main Cluster Disassembly
WARNING
• WHEN MAKING TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE KEY.
- DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST.
- DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
- REMOVE SPARK PLUG WIRE.
• CLEAN TRANSMISSION BEFORE DISASSEMBLY.
• SEE SAFETY WARNINGS, PAGE 17-1.
1. Place two flat steel bars no more than .100 inch (2.54 millimeters) thick between the reverse gear (49)
and synchronizer ring (42). Using a press ram and an 11/16 inch diameter arbor, press against the end
of the shaft to remove bearing (38), Belleville spring (73), thrust washer (39), reverse gear (49), syn-
chronizer ring (42) and thrust washer (43) (Figure 17-3, Page 17-3) (See Figure 17-16).
WARNING
• PREVENT THE OUTPUT SHAFT FROM DROPPING TO THE FLOOR AFTER PRESSING ON IT.
• MAKE SURE THE FLAT STEEL BARS ARE AGAINST THE REVERSE GEAR AND NOT THE SYN-
CHRONIZER.
2. Slide clutch hub assembly (45-48) off shaft (44). Slide the synchronizer ring (42) that is a part of the for-
ward gear assembly off the shaft (Figure 17-18, Page 17-10).
3. Place the two flat steel bars under the forward gear (41). Using a press ram with an 11/16 inch diame-
ter arbor, press against the end of the shaft to remove the bearing (38), thrust washer (39), forward
gear (41), and thrust washer (43) (Figure 17-3, Page 17-3) (See Figure 17-17).
WARNING
• PREVENT THE OUTPUT SHAFT FROM DROPPING TO THE FLOOR AFTER PRESSING ON IT.
PRESS RAM
11/16" DIAMETER
ARBOR
INSERT FLAT
BARS UNDER
FORWARD
GEAR (41)
(SEE FIGURE 17-3)
FIGURE 17-17
17
G
Page 17-9