Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 115 / 544

Page 9-5
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9
INSTALLING THE AXLE SHAFT
1. Clean the bearing and seal seats in the axle tube (16 or 39) (Figure 9-1, Page 9-1).
2. Place a new seal (17) (Figure 9-1) in the axle tube with the seal lip facing away from the bearing. Use
an axle seal tool (Club Car Part No. 1014162) and mallet to tap it in until it seats firmly in position (Fig-
ure 9-6). A hydraulic press may also be used with the axle seal tool.
3. Clean the shaft splines and then insert the shaft, splined end first, through the seal and into the axle
tube. Be careful not to damage the seal. Then advance the shaft through the inner bearing and rotate it
to align the shaft splines with the splined bore of the differential side gear. Continue advancing the shaft
until the bearing seats against the axle tube shoulder.
4. Using snap ring pliers, install the retaining ring (6) (Figure 9-1) in the axle tube.
5. Place a 1/4” to 3/8” (6 to 10 millimeter) diameter rod against the retaining ring and tap lightly at four to
five locations to ensure that it is properly seated.
REMOVING THE TRANSAXLE
REMOVING THE TRANSAXLE - DS GASOLINE
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jackstands under the frame cross-member between the spring mount and the side stringer, just forward
of each rear wheel. Lower the vehicle to let the jackstands support the vehicle (Figure 9-7, Page 9-6).
• BE SURE THAT THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE. IF THE RING IS
NOT PROPERLY INSTALLED, THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE
AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS. LOSS OF VEHICLE CON-
TROL COULD RESULT, CAUSING SEVERE PERSONAL INJURY.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY BEFORE SERVICING THE VEHICLE.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERY OR ELECTRICAL CON-
NECTIONS.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING:
- DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
• FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, INNER FRAME, OR
OTHER METAL COMPONENT.
WARNING
WARNING