Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 297 / 544

Page 17-11
G
17
1. Remove the two synchro springs (45) from both sides of the clutch hub assembly (Figure 17-19).
2. Slide the sleeve (48) off the clutch hub (46) (Figure 17-19).
3. Remove the synchro inserts (47) (Figure 17-19).
Input Shaft Disassembly
1. Use external snap ring pliers to remove two snap rings (63) from the input shaft (65) (Figure 17-20).
2. Remove the input gear (64) (Figure 17-20).
3. Press the bearing (38) off the shaft (65) (Figure 17-20).
Shift Arm Disassembly
1. Slide the shift rod (71) out of the sleeve shift arm (70) (Figure 17-21). The shift rod has three detent
locations for the ball to rest. As the shift rod is coming out, be prepared for the ball and spring to fly out
of the sleeve shift arm because the spring will be compressed as the rod is moving out of the way.
2. Remove shifter ball (69) and shifter spring (68 (Figure 17-21)).
3. Remove roll pin (72) out of the shift rod (Figure 17-21).
Transmission Housing Disassembly
1. Remove the oil seal (30) from input shaft bore using a punch and light hammer (Figure 17-3, Page 17-
3). Tapping from the inside of the housing, drive the seal out of the bore. (Figure 17-22).
FIGURE 17-21 FIGURE 17-22
• DO NOT ALLOW THE PUNCH TO TOUCH THE INSIDE DIAMETER OF THE BORE.
FIGURE 17-23 FIGURE 17-24
72
71
70
68
69
HOUSING
SEAL
NOTE
29
22
23
POSSIBLE OIL
TRANSMISSION
HOUSING
ROTATE SHIFT ARM LEVER (67) UP
UNTIL ROLL PIN HOLE ALIGNS WITH
AIR BREATHER HOLE ON
TOP OF HOUSING.
REMOVE PIN WITH PUNCH
5/32 IN,
(4 MM)
PUNCH
ROLL PIN (66)