Club Car Gasoline Service Manual page 307

FIGURE 17-43
11. Using a depth gauge, measure the distance from the gasket surface of the housing to the side of gear
(62) on the input shaft (Figure 17-43). Use the table to determine which thrust washer to use.
MEASURED DISTANCE INCHES (MILLIMETERS)
Less than .1260 inches (3.2 millimeters)
More than .1260 inches (3.2 millimeters) but less than .1378 inches (3.5 millime-
ters)
More than .1378 inches (3.5 millimeters)
12. Clean the gasket surface on the cover and housing. Install a new gasket on the housing (Figure 17-10,
Page 17-6).
NOTE
• BE SURE GASKET SURFACE ON THE COVER AND HOUSING HAS BEEN THOROUGHLY
CLEANED AND IS DRY. DO NOT USE GASKET SEALERS.
13. Install assembled cover to housing. Seat the cover completely against the housing with HANDS ONLY.
If the cover will not seat, check if the gear teeth are meshing properly. The reverse idler gear will mesh
with gears on both the input and output shafts.
14. Install bolts (52 and 35), first tightening the bolts down evenly with fingers. Torque the bolts in proper
sequence to 5-7 ft. lbs. (6.7/9.5 N-m). If the bolts are not tightened in this sequence, it may cause the
cover to warp (Figure 17-44).
15. Install the lower drain plug and gasket and torque to 25 ft. lbs. (34 N-m) (Figure 17-2, Page 17-2).
INSTALLATION OF THE TRANSMISSION
1. Install transmission into the vehicle. Rotate the transmission so the output shaft lines up with the spline
shaft on the transaxle.
2. Install the three 1/4 x 4" retaining bolts (A,B,C) and three washers through the forward and reverse
shifter cable bracket (1), the transaxle and the transmission. Use three nylon locknuts and three wash-
ers to secure the three components together. Torque nuts to 75-95 in. lbs. (8.5/10.7 N-m) (Figure 17-7,
Page 17-4).
3. Install the lower 5/16 x 1" bolt (D) through the support bracket then the transmission into the transaxle.
Torque the bolt to 17 ft. lbs. (23 N-m) (Figure 17-7, Page 17-4).
4. Attach the shift cable to the bracket and tighten the two adjustment nuts (1). Connect the forward and
reverse shift cable to the transmission shifter arm (Figure 17-5, Page 17-4). Adjust the cable (See For-
ward And Reverse Shifter Cable Adjustment, Page 17-24).
TRANSMISSION COVER
OUTPUT SIDE
1
3
62
5
THRUST WASHER CLUB CAR PART NO.
1012723
1012724
1012725
CLUB CAR
4
MADE IN JAPAN
52
35
FIGURE 17-44
Page 17-21
17
G
2