Page 17-17
G
17
1. Slide the thrust washer (43) onto the end of the output shaft with the inner spline. Place the gear
assembly (49) (wider gear), new thrust washer (39), Belleville spring washer (73) and the ball bearing
(38) onto the end of the output shaft. Using a press ram and a press sleeve that will only apply pressure
to the inner race of the bearing, press the main cluster components parts onto the shaft until the bear-
ing is fully seated against Belleville spring and thrust washer. Be sure gear rotates freely.
2. Turn the shaft around so the other end is facing up. Install the synchronizer ring (42) onto the reverse
gear (49) that has been reinstalled onto the shaft in the preceding step.
3. Install the assembled clutch hub and sleeve onto the output shaft (44).
4. Install thrust washer (43), synchronizer ring (42), forward gear (41), new thrust washer (39), Belleville
spring washer (73) and ball bearing (38) onto the other end of the output shaft. Using a press ram and
a press sleeve that will only apply pressure to the inner race of the bearing, press until bearing (38) is
fully seated against Belleville spring and thrust washer.
Shifter Arm Assembly (Figure 17-21, Page 17-11)
1. Install roll pin (72) into shift rod (71) bore with pin protruding equally on both sides of rod, approximately
.100 inch (2.54 millimeters).
2. Install shifter spring (68) and shifter ball (69) into bore of the shifter arm (70). With long arm of shifter
arm on your right, push the shift rod (71) into the bore of the shifter arm (70). Using a punch to depress
the shifter ball, insert the shift rod (71) to the center (Neutral) detent position.
Governor Assembly
1. Place lower washer (17) into governor shaft bore (Figure 17-15, Page 17-8).
2. Install middle retaining ring (16) in the center groove on the governor arm shaft (18) (Figure 17-35).
3. Apply a light film of new transmission lubricant to the governor arm shaft (18) and governor shaft bore.
• APPLY CLEAN TRANSMISSION LUBRICANT TO THE INSIDE DIAMETERS OF GEARS (49 AND
41) AND SYNCHRONIZER RINGS (42).
• MAKE SURE THAT BOTH GEARS ON THE OUTPUT SHAFT CAN ROTATE FREELY.
• DO NOT USE ANY LUBRICANT OTHER THAN TRANSMISSION OIL ON THE GOVERNOR SHAFT.
FIGURE 17-35
FIGURE 17-36
NOTE
NOTE
NOTE
16
B
GOVERNOR ARM SHAFT INSTALLED
IN SHAFT BORE WITH MIDDLE
AND LOWER
RETAINING
RINGS
18
A
16
17
GOVERNOR
SHAFT CAP JIG
A
B
OIL SEAL
PRESS JIG
24
17
16
24
Summary of Contents for 1996 DS Golf Car Gasoline
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Page 544: ...Golf Cars Club Car Inc P O Box 204658 Augusta GA 30917 4658...