Transaxle Assembly - Club Car 1998 Maintenance And Service Manual Supplement

16
TRANSAXLE
9.6. Remove the idler gears and thrust plates (38 and 35) (Figure 16-4, Page 16-4) or (29 and 28) (Figure
16-5, Page 16-5).
9.7. Remove the differential gears and thrust plates (34 and 37) (Figure 16-4, Page 16-4) or (30 and 27) (Fig-
ure 16-5, Page 16-5). See also Figure 16-20, Page 16-11.
9.8. Inspect the bearings (14) (Figure 16-4, Page 16-4) or (13) (Figure 16-5, Page 16-5) of the differential
case and replace them if they are damaged. To remove them, press them off. See CAUTION at bottom
of page 16-10.
10. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE.
NOTE
• DAMAGED OR WORN GEARS SHOULD BE REPLACED AS SETS.

TRANSAXLE ASSEMBLY

CAUTION
• DO NOT PRESS AGAINST THE BEARING OUTER RACE.
• TYPE K TRANSAXLES: GASKET (13) FACES OF THE HOUSING MUST BE CLEAN AND SMOOTH. USE ONLY A NEW
GASKET THAT IS NOT TORN OR DAMAGED. THE GASKET MUST LIE FLAT AGAINST THE HOUSING FACES (FIGURE
16-4, PAGE 16-4).
• THE HOUSING AND ALL PARTS MUST BE WIPED CLEAN AND DRY BEFORE REASSEMBLY.
1. If bearings (14) (Figure 16-4, Page 16-4) or (13) (Figure 16-5, Page 16-5) were removed during disassembly,
install new bearings using an arbor press.
2. Assemble the differential gear case:
2.1. Install the pin (31) (Figures 16-4 or 16-5, Pages 16-4 or 16-5). Apply a small amount of oil to all thrust
plates and to both ends of the pin.
• Type K transaxles:
2.2. While aligning the dowel pin, assemble the two halves of the differential gear case (33 and 36) and rein-
stall the output gear (30) (Figure 16-4, Page 16-4).
2.3. Install eight hex bolts (28) and the bolt lock plates (29) (Figure 16-4, Page 16-4). 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 16-17, Page 16-11).
2.5. If the large gear (23) was removed from the intermediate gear, insert key (22) into the keyway in the
shaft and then press the large gear and the bearing (18) onto the shaft. Be sure the key is properly posi-
tioned in the keyway before attempting to press on the large gear and bearing (Figure 16-4, Page 16-
4).
• Type G transaxles:
2.6. Install four hex bolts (33) and output gear (32). Tighten bolts to 51 ft.lb (69 N-m) (Figure 16-5, Page 16-
5).
• All Transaxles:
3. Press a new bearing (20) (Figure 16-4, Page 16-4) or (18) (Figure 16-5, Page 16-5) onto the intermediate
gear assembly.
4. Press new bearing (18) (Figure 16-4, Page 16-4) or (16) (Figure 16-5, Page 16-5) onto input pinion gear.
5. Apply grease to the lip of the new oil seal (10) (Figures 16-4 or 16-5, Pages 16-4 or 16-5) and install the seal
using a transaxle pinion seal tool (Club Car Part No. 1014161). The lip of the oil seal should face the inside of
the transaxle housing. Make sure the seal is firmly seated.
Page 16-12 1998/1999 PowerDrive Plus Maintenance and Service Supplement
Transaxle Disassembly, Inspection and Assembly