Transaxle Assembly - Club Car Precedent 2004 Maintenance And Service

16A
TRANSAXLE (TYPE G)

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 16a-5, Page 16a-3).
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figure 16a-5, Page 16a-3). Apply a small amount of oil to all thrust plates and
to both ends of the pin.
2.2. Install four hex bolts (33) and output gear (32). Tighten bolts to 51 ft-lb (69 N·m).
3. Press a new bearing (18) onto the intermediate gear assembly (Figure 16a-5, Page 16a-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, the intermediate gear assembly, and the input pinion gear simulta-
neously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation (Figure 16a-11, Page 16a-6).
7. Install both dowel pins (25) in the transaxle housing (20) (Figure 16a-5, Page 16a-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 16a-5, Page 16a-3).
8.3. Install eleven 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 lock washers and bolts (9 and 8) (Figure 16a-5, Page 16a-3).
Tighten the bolts to 36 ft-lb (49 N·m).
9. Install the brake assemblies as instructed. See Brake Cluster Installation, Section 6, Page 6-10.
10. Apply a small amount of grease to the lip of the oil seal (15) (Figure 16a-5, Page 16a-3).
∆
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, See following NOTE.
NOTE: There is a LEFT and RIGHT side axle. The splined portions on the axles that insert into the trans-
axle case are two different lengths. The longest length spline is the LEFT, or driver side axle.
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
Page 16a-10 2004 Precedent IQ System Golf Car Maintenance and Service Manual
Transaxle Disassembly, Inspection, and Assembly