Club Car Gasoline Service Manual page 303

NOTE
• APPLY CLEAN TRANSMISSION LUBRICANT TO THE INSIDE DIAMETERS OF GEARS (49 AND
41) AND SYNCHRONIZER RINGS (42).
1. Slide the thrust washer (43) onto the end of the output shaft with the inner spline. Place the gear
assembly (49) (wider gear), new thrust washer (39), Belleville spring washer (73) and the ball bearing
(38) onto the end of the output shaft. Using a press ram and a press sleeve that will only apply pressure
to the inner race of the bearing, press the main cluster components parts onto the shaft until the bear-
ing is fully seated against Belleville spring and thrust washer. Be sure gear rotates freely.
2. Turn the shaft around so the other end is facing up. Install the synchronizer ring (42) onto the reverse
gear (49) that has been reinstalled onto the shaft in the preceding step.
3. Install the assembled clutch hub and sleeve onto the output shaft (44).
4. Install thrust washer (43), synchronizer ring (42), forward gear (41), new thrust washer (39), Belleville
spring washer (73) and ball bearing (38) onto the other end of the output shaft. Using a press ram and
a press sleeve that will only apply pressure to the inner race of the bearing, press until bearing (38) is
fully seated against Belleville spring and thrust washer.
NOTE
• MAKE SURE THAT BOTH GEARS ON THE OUTPUT SHAFT CAN ROTATE FREELY.
Shifter Arm Assembly (Figure 17-21, Page 17-11)
1. Install roll pin (72) into shift rod (71) bore with pin protruding equally on both sides of rod, approximately
.100 inch (2.54 millimeters).
2. Install shifter spring (68) and shifter ball (69) into bore of the shifter arm (70). With long arm of shifter
arm on your right, push the shift rod (71) into the bore of the shifter arm (70). Using a punch to depress
the shifter ball, insert the shift rod (71) to the center (Neutral) detent position.
Governor Assembly
1. Place lower washer (17) into governor shaft bore (Figure 17-15, Page 17-8).
2. Install middle retaining ring (16) in the center groove on the governor arm shaft (18) (Figure 17-35).
3. Apply a light film of new transmission lubricant to the governor arm shaft (18) and governor shaft bore.
NOTE
• DO NOT USE ANY LUBRICANT OTHER THAN TRANSMISSION OIL ON THE GOVERNOR SHAFT.
GOVERNOR ARM SHAFT INSTALLED
IN SHAFT BORE WITH MIDDLE
AND LOWER
A
RETAINING
18
16
17
FIGURE 17-35
B
RINGS
16
GOVERNOR
OIL SEAL
SHAFT CAP JIG
PRESS JIG
24
A
16
17
FIGURE 17-36
17
B
24
Page 17-17
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