Club Car 1997 DS, Maintenance Service Supplement

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Page 49
G
10
7. Turn the case section containing the gearing on edge as shown (Figure 10-37). While holding it in this
position, gently rock all of the gear assemblies to loosen them slightly in their seating.
8. When all of the gear assemblies are slightly loosened, remove the differential gear case assembly by
gently rocking it while pulling it from the casing (Figure 10-38).
9. Continue to rock and loosen the remaining gear assemblies until the intermediate gear assembly can
be removed from the casing (Figure 10-39, Page 50). Then remove the idler shaft assembly.
10. Remove the synchronizer gear assembly and shift fork assembly as a unit from the casing (Figure 10-
39, Page 50).
11. Use a seal puller (Club Car Part No. 1012809) or rolling wedge bar to remove the input shaft oil seal
from the casing (Figure 10-40, Page 50).
12. Remove the oil flow guide (Figure 10-41, Page 50) from the casing.
13. Remove the shifter shaft (Figure 10-41, Page 50) from the casing.
13.1. Use snap ring pliers to remove the shaft retaining ring (11) on the outside of the casing as shown
(Figure 10-36).
13.2. Remove the flat washer (12) from the shaft on the outside of the casing as shown (Figure 10-36),
then remove the shifter shaft by pushing it through the casing wall toward the interior of the tran-
saxle.
13.3. Use a seal puller to remove the shifter shaft oil seal (13) from the casing (Figure 10-36).
14. Use a 14 mm open end wrench to remove the breather (31) from the casing (Figure 10-36).
15. Remove the governor assembly from the casing.
15.1. Remove the cotter pin (20) and flat washer (21) from the pivot arm (Figure 10-36).
• TO PREVENT DAMAGE TO THE GEARS, USE EXTREME CARE WHEN HANDLING THEM.
FIGURE 10-37 FIGURE 10-38
CAUTION
HOLD CASING UPRIGHT AND GENTLY
ROCK EACH GEAR ASSEMBLY UNTIL
ALL ARE SLIGHTLY LOOSENED IN
THEIR SEATINGS
WHILE GENTLY ROCKING DIFFERENTIAL
GEAR CASE, PULL IT FROM ITS SEATING
DIFFERENTIAL
GEAR CASE
ASSEMBLY