Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 298 / 544

Page 17-12
17
G
Transmission Housing Disassembly, Continued:
2. Remove air breather (29) and use a high flash-point solvent to clean the air breather (Figure 17-23,
Page 17-11).
3. Inspect the shifter shaft (22). If there is oil around the opening, the O-ring (23) should be replaced. If
there is no oil, disregard steps 4, 5, and 6 below (Figure 17-23, Page 17-11).
4. Mark the inside shifter arm lever with paint or a punch an orientation mark so it can be reinstalled fac-
ing correctly. Rotate the shaft until the roll pin can be seen through the breather hole. Remove roll pin
(66) by using a 5/32 inch (4 millimeters) punch through the breather hole, driving the roll pin into the
open area of the transmission housing (Figure 17-24, Page 17-11).
5. Remove shifter shaft (22) and O-ring (23) from shifter shaft.
6. Remove inside shifter arm lever (67).
Cover Disassembly
1. Inspect the gear (58) and bearing (57) on the idler shaft (59). If the bearing has abnormal play or the
gear has wear, replace both the gear and the bearing (Figure 17-25).
1.1. Remove flange nut (51) from cover (53) (Figure 17-25).
1.2. Press idler shaft (59) out (Figure 17-25).
1.3. Remove O-ring (55), thrust washer (56), needle bearing (57) and reverse idler gear (58) from idler
shaft (59).
2. Remove the oil seal (31) (Figure 17-3, Page 17-3) from output shaft bore using a punch and light ham-
mer. Tapping from the inside of the cover, drive the seal out of the bore (Figure 17-22, Page 17-11).
3. If the needle bearing (60) (Figure 17-3, Page 17-3) that supports the input shaft is damaged, insert a
small chisel between the outer race and retainer of the needle bearing and drive it into the bearing by
tapping on it with a light hammer (Figure 17-26). Then use the chisel to pry the retainer out of the bear-
ing (Figure 17-27). Discard the retainer and rollers.
• USE OF ANOTHER SIZE PUNCH MAY DAMAGE THE ROLL PIN. THIS COULD MAKE THE
REMOVAL OF THE ROLL PIN VERY DIFFICULT.
• USE CARE WHEN DRIVING THE ROLL PIN TO MAKE SURE THE PUNCH DOES NOT DAMAGE
THE THREADS IN THE BREATHER HOLE.
FIGURE 17-25 FIGURE 17-26
CAUTION
55
51
51
53
53
PRESS
IN OIL
SEAL (31)
APPLY
GREASE
AROUND "O"
RING
IF NEEDLE BEARING (60)
WAS REMOVED, APPLY
OIL,PRESS IN
NEW BEARING
IDLER SHAFT
ASSEMBLY
56
57
58
59
31
60