Club Car Precedent 2004 Maintenance And Service page 199

TRANSAXLE (TYPE K)
2.3. Install eight hex bolts (28) and the bolt lock plates (29). Tighten the bolts to 18 ft-lb (24 N·m).
2.4. Bend the edges of the bolt locking tabs securely against the flats of the bolt heads to prevent the
bolts from loosening and possibly causing damage (Figure 16b-16, Page 16b-9).
2.5. If the large gear (23) was removed from the intermediate gear, insert key (22) into keyway in the
shaft and then press the large gear and the bearing (18) onto the shaft. Be sure the key is properly
positioned in the keyway before attempting to press on the large gear and bearing (Figure 16b-4,
Page 16b-3).
3. Press a new bearing (20) onto the intermediate gear assembly (Figure 16b-4, Page 16b-3).
4. Press new bearing (18) onto input pinion gear (19).
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 16b-12, Page 16b-7).
7. Install both dowel pins (27) in the transaxle housing (24) (Figure 16b-4, Page 16b-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 (24) (Figure 16b-4, Page 16b-3).
8.3. Install the ten bolts (26) and tighten to 69 in-lb (7.8 N·m).
8.4. If the axle tube (16 and 40) was removed, install the shims (39), (if the shims were removed) and
Three Bond liquid gasket. Install the axle tube with five lock washers and bolts (9 and 8). Tighten
the bolts to 36 ft-lb (49 N·m).
NOTE: If the differential case (33 and 36), the transaxle housing (11 and 24) or axle tube (16 and 40)
(Figure 16b-4, Page 16b-3) was replaced, shim the transaxle. See Shimming the Transaxle on
page 16b-12.
9. Install the brake assemblies as instructed. See Brake Cable Installation, Section 6, Page 6-12.
10. Apply a small amount of grease to the lip of the oil seal (17) (Figure 16b-4, Page 16b-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 (1 and 2) 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 16b-4, Page 16b-3).
2004 Precedent IQ System Golf Car Maintenance and Service Manual
Transaxle Disassembly, Inspection, and Assembly
16B
Page 16b-11