Club Car 1997 DS, Maintenance Service Supplement

Page: 60 / 164

Page 52
10
G
DISASSEMBLE THE SYNCHRONIZER GEAR ASSEMBLY
1. Place a bearing puller wedge attachment (Club Car Part No. 1012812) between the bearing (38) and
spur (governor drive) gear (40) (Figure 10-43, Page 53), then press the bearing off the input shaft as
shown (Figure 10-49, Page 9-55). See CAUTION above.
2. Pull the spring (Belleville) washer (39), spur gear (40), dowel pin (50), thrust plate (41), input gear
assembly (42), large needle bearing (43), small needle bearing (44), synchronizer ring (45), and thrust
plate (41) from the input shaft (Figure 10-43, Page 53).
3. Place a bearing puller wedge attachment (Club Car Part No. 1012812) between the bearing (54) and
input gear assembly (52) (Figure 10-43), then press the bearing off the input shaft as shown (Figure
10-50, Page 55).
4. Pull the spring (Belleville) washer (39), thrust washer (53), input gear assembly (52), two needle bear-
ings 43 and 44), thrust plate (41), and synchronizer ring (45) from the input shaft (Figure 10-43).
5. Use a small flat-blade screwdriver to remove two synchronizer springs (snap rings) (46) (Figure 10-
43), and then slide the synchronizer clutch hub (49) (Figure 10-43) from the input shaft (51).
6. Remove the three synchronizer inserts (48) (Figure 10-43) from the synchronizer sleeve.
7. Press the synchronizer sleeve (47) from the input shaft (Figure 10-43).
DISASSEMBLE THE INTERMEDIATE GEAR ASSEMBLY
1. Place a bearing puller wedge attachment (Club Car Part No. 1012812) between the bearing (38) and
shaft/gear (56) (Figure 10-43), then press bearing off the shaft as shown (Figure 10-51, Page 56).
• MARK PARTS FOR IDENTIFICATION AS THEY ARE DISASSEMBLED. PARTS MUST BE REAS-
SEMBLED IN THEIR ORIGINAL LOCATIONS AND ORIENTATIONS.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THE
SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THE
SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF.
• THERE ARE THREE SYNCHRONIZER INSERTS (48) SET INTO SLOTS IN THE SYNCHRONIZER
SLEEVE (47) (Figure 10-43). THESE MAY FALL FREE WHEN THE SYNCHRONIZER CLUTCH
HUB (49) IS REMOVED. TAKE CARE TO NOT LOSE THESE INSERTS.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THE
SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF.
CAUTION
CAUTION
CAUTION
NOTE
CAUTION