Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 124 / 544

Page 9-14
9
E
G
Transaxle Assembly, Continued:
19. Clean the splines on the axle shaft (1 and 2) (Figure 9-1) and insert the shaft, splined end first, through
the seal. Be very careful not to damage the seal. Advance the shaft through the inner bearing and then
rotate it to align the shaft splines with the splined bore of the differential side gear. Push the shaft in
until the bearing seats against the shoulder in the axle tube.
20. Install the retaining ring (6) (Figure 9-1, Page 9-1) in the axle tube using snap ring pliers.
21. Make sure that the drain plug is installed in the transaxle and tightened to 18-25 ft.lbs. (24/34 N-m).
Using a funnel, fill the transaxle through the level indicator hole, with 22 ounces of SAE 30 API Class
SE, SF, or SG oil (a higher grade may be used). Install and tighten the level indicator hole plug to 18-25
ft.lbs. (24/34 N-m).
SHIMMING THE TRANSAXLE
If the differential cage (32 and 37) (Figure 9-1), transaxle housing (11 and 24) (Figure 9-1), or axle tube (16
and 39) (Figure 9-1) has been replaced, the transaxle may need new shims. To determine whether new
shims are necessary, the transaxle must be completely assembled except for the short axle tube (16) (Fig-
ure 9-1) and both axle shafts (1 and 2) (Figure 9-1).
1. Stand the transaxle on end, on the axle tube.
2. Using a depth gauge, measure the distance from the gasket seal surface of the axle tube (gasket must
be removed) to the outer race of the bearing (14) (Figure 9-1) on the differential cage (32) (Figure 9-1)
(See Figure 9-25).
3. Use the chart below to determine whether shimming is required and, if so, how many shims (Club Car
Part No. 1013781) should be used.
• 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.
FIGURE 9-25
WARNING
1
10
20
30
40
50
60
70 80
90
Distance from gasket seal surface
to outer race or bearing -
INCHES (MM)
SHIMS
REQUIRED
Up to .134 inches (3.4 mm) 0
.134 - .142 inches (3.4 - 3.6 mm) 1
.142 - .150 inches (3.6 - 3.8 mm) 2
.150 - .155 inches (3.8 - 3.9 mm) 3