Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 121 / 544

Page 9-11
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E
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5. Use a bearing puller or arbor press to remove bearings (18) (Figure 9-1, Page 9-1) from the input pin-
ion gear. If the oil seal (10) (Figure 9-1) is damaged, replace it. See CAUTION below.
6. To disassemble the intermediate gear assembly, press off together the bearing (18) and the gear (23)
(Figure 9-1, Page 9-1) (See Figure 9-19).
7. Remove the key (22) (Figure 9-1, Page 9-1)(See Figure 9-20).
8. Press the bearing (20) (Figure 9-1, Page 9-1) off of the intermediate gear assembly.
9. Disassemble the differential cage gear:
9.1. Bend down the bolt lock plates (29) (Figure 9-1, Page 9-1) on the ring gear (30) (Figure 9-1)
(See Figure 9-21).
9.2. Remove the eight hex bolts (28) (Figure 9-1) that secure the ring gear to the differential cage.
9.3. Remove the ring gear. Retain the dowel pin from between the ring gear and differential cage for
reassembly.
9.4. Separate the differential cage gear housing. If necessary, screw two of the hex bolts (removed in
step 9.2.) back into the differential gear unit and, while holding the unit slightly above the work-
bench, tap lightly on the bolt heads (Figure 9-22). Remove the two bolts.
9.5. Remove the differential pin (31) (Figure 9-1, Page 9-1) by pushing it through from one side (Fig-
ure 9-23, Page 9-12).
• DO NOT REUSE BEARINGS AFTER REMOVING THEM. REPLACE THEM WITH NEW ONES.
• SEVERAL DIFFERENTIAL CAGE GEAR CONFIGURATIONS WERE MANUFACTURED IN 1995
AND 1996. IF YOU DISASSEMBLE THE CAGE GEAR ASSEMBLY, IT IS IMPORTANT THAT YOU
NOTE ITS CONFIGURATION. POSSIBLE GEAR ASSEMBLY CONFIGURATIONS ARE:
- THRUST WASHERS (1, 2, 3, AND 4) (FIGURE 9-24, PAGE 9-12), AND THE LOCK PLATES (FIG-
URE 9-21) ARE INCLUDED.
- THRUST WASHERS (1, 2, AND 3) (FIGURE 9-24, PAGE 9-12), AND THE LOCK PLATES (FIG-
URE 9-21) ARE NOT INCLUDED.
- THRUST WASHER (3) (FIGURE 9-24, PAGE 9-12) AND THE LOCK PLATE (FIGURE 9-21) ARE
NOT INCLUDED.
FIGURE 9-21 FIGURE 9-22
CAUTION
CAUTION
DOWEL PIN LOCK PLATE
TO SEPARATE HOUSING,
IT MAY BE NECESSARY TO
INSERT HEX HEAD BOLTS
INTO HOUSING AND
TAP LIGHTLY