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Page 35
SECTION
10
G
SECTION 10 - UNITIZED TRANSAXLE
This section supersedes Sections 9 and 17 in the 1995-1996 DS Maintenance and Service Manual.
GENERAL INFORMATION
All 1997 model gasoline powered DS Golf Cars are equipped with heavy-duty, fully-synchronized Unitized
Transaxles. The unitized transaxle replaces the transmission / transaxle combination that was used previ-
ously, and performs the functions of both; utilizing fully synchronized internal gearing to change vehicle direc-
tion. Because the unitized transaxle is used to reverse vehicle direction, the engine, drive clutch, belt, and
driven clutch rotate in one direction, and therefore engine and clutches are not subjected to reversing loads.
This reduces maintenance requirements on the engine and clutches. With the unitized transaxle, power is
transfered from the engine through the drive clutch, the drive belt, the driven clutch, and then through the
unitized transaxle to the wheels.
A shifter lever, connected to a shifter arm on the unitized transaxle, is used to change the gears to one of
three shift positions: forward (F), neutral (N), or reverse (R) (Figure 10-1, Page 36). See NOTE below.
The unitized transaxle is extremely durable and should require very little service under normal operating con-
ditions. The vehicle should always be stopped before changing vehicle direction. The only service required
on the unitized transaxle is to maintain proper lubricant level (See Gasoline Vehicle Lubrication, Page 7 in
this supplement). Under normal operating conditions, weekly adjustment to the system should not be
required.
The governor system is a flyweight type, and measures ground speed of the vehicle. It is mounted inside the
unitized transaxle and is driven by transmission gears. Because the governor is mounted inside the trans-
axle, it is protected from abuse and damage that is common to externally mounted governor systems. If any
of the governor linkage is removed in order to service other components, readjustment of the governor link-
age is required (See Governor Cable Installation and Adjustment, Page 140 in this supplement).
• DURING NORMAL VEHICLE OPERATION, A NEUTRAL LOCK-OUT FEATURE PREVENTS THE
ENGINE FROM RUNNING WHEN THE FORWARD AND REVERSE SWITCH IS IN THE NEUTRAL
POSITION (SEE NEUTRAL LOCK-OUT CIRCUIT, SECTION 12, PAGE 12-6 IN THE MAINTE-
NANCE AND SERVICE MANUAL).
• A SPECIAL NEUTRAL LOCKOUT CAM IS PROVIDED TO ALLOW MAINTENANCE PERSONNEL
TO RUN THE ENGINE IN NEUTRAL FOR CERTAIN TESTS AND MAINTENANCE PROCEDURES.
WHEN THE NEUTRAL LOCK-OUT CAM IS IN THE SERVICE POSITION, THE VEHICLE WILL
RUN WHEN THE FORWARD AND REVERSE SWITCH IS IN THE NEUTRAL POSITION, BUT WILL
NOT RUN WHEN THE FORWARD AND REVERSE SWITCH IS IN THE FORWARD OR REVERSE
POSITION (SEE NEUTRAL LOCK-OUT CIRCUIT, SECTION 12, PAGE 12-6 IN THE MAINTE-
NANCE AND SERVICE MANUAL).
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED
IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
NOTE
WARNING
Summary of Contents for 1997 DS
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