Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 302 / 544

Page 17-16
17
G
Cover Assembly, Continued:
3. If input shaft needle bearing (60) was removed, press in a new bearing (Figure 17-25, Page 17-12).
4. Install the idler shaft assembly into the cover. Torque nut to 36-50 ft. lbs. (49/68 N-m). Be sure reverse
idler gear rotates freely (Figure 17-25, Page 17-12).
Input Shaft Assembly (Figure 17-20, Page 17-10)
1. Install the input gear (64) on input shaft (65). Install the two snap rings (63) onto the input shaft.
2. Press bearing (38) up against the input gear (64) on the input shaft.
Clutch Hub Assembly (Figure 17-19, Page 17-10)
1. Install the clutch hub (46) into the sleeve (48).
2. Install the three synchro inserts (47) with the lip of the synchro inserts facing the center of the hub. Hold
the synchro inserts in place from underneath.
3. Install the synchro spring (45) under the lip of all three synchro inserts (Figure 17-19, Page 17-10).
Install the other synchro spring on the other side of the clutch hub.
Main Cluster Assembly (Figure 17-18, Page 17-10)
• PRESS ONLY AGAINST OUTER RACE OF BEARING.
• APPLY CLEAN TRANSMISSION OIL TO NEEDLE BEARING AND APPLY GREASE AROUND THE
O-RING.
• THE FLAT SURFACE OF THE INPUT GEAR SHOULD FACE THE SNAP RING.
• THE HOOKED END OF THE SYNCHRO SPRING SHOULD TOUCH THE INSIDE OF THE SLEEVE.
• CHECK TO BE SURE THE SLEEVE (48) CAN SLIDE ON THE CLUTCH HUB (46).
• WHEN MAKING TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE KEY.
- DISCONNECT BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
- REMOVE SPARK PLUG WIRE.
• CLEAN TRANSMISSION BEFORE DISASSEMBLY.
• SEE SAFETY WARNINGS, PAGE 17-1.
CAUTION
NOTE
NOTE
NOTE
WARNING