Club Car 1997 DS, Maintenance Service Supplement

Page: 65 / 164

Page 57
G
10
SYNCHRONIZER GEAR ASSEMBLY
1. Press the synchronizer sleeve (47) (Figure 10-43, Page 53) onto the splines of the input shaft. No par-
ticular orientation of the sleeve is necessary, but toward the short end of the shaft, the machined circu-
lar face surrounding the ends of the internal splines in the sleeve must be flush with the machined lip of
the shaft at the ends of the shaft splines (See Figure 10-57).
2. Install the snap rings (46) (Figure 10-43, Page 53) in the sleeve as shown (Figure 10-58).
3. Install the three synchronizer inserts (48) into the slots in the sleeve as shown (Figure 10-43, Page
53). Make sure the notched surfaces of the inserts are facing outward as shown (Figure 10-59).
4. Install the synchronizer clutch hub (49) (Figure 10-43) onto the synchronizer sleeve. Make sure that
the gear end of the hub is oriented toward the long end of the input shaft as shown (Figure 10-60,
Page 58).
5. On the long end of the shaft, install the synchronizer ring (45) (Figure 10-43, Page 53) with the smooth
collar of the ring towards the clutch hub. Make sure that the three notches in the collar mate with the
synchronizer inserts in the synchronizer sleeve as shown (Figure 10-61, Page 58).
FIGURE 10-55 FIGURE 10-56
FIGURE 10-57 FIGURE 10-58
• MAKE SURE THAT THE ENDS OF THE SNAP RINGS ARE POSITIONED BETWEEN THE SYN-
CHRONIZER INSERT SLOTS.
SYNCHRO RING MUST BE
REPLACED WHEN
(X) DISTANCE IS LESS
THAN .020 IN (0.51 MM)
X
PRESS BEARING
ONTO IDLER SHAFT
TURN IDLER SHAFT
OVER AND PRESS
BEARING ON
OTHER END
B
A
PRESS
RAM
SYNCHRONIZER
SLEEVE
INPUT
SHAFT
MACHINED
FACE OF
SYNCHRO.
SLEEVE
TOP OF SPLINE PRESSED
LEVEL WITH MACHINED
FACE
TOP OF SPLINE
INSTALL SNAP RINGS
ON BOTH SIDES OF
SYNCHRONIZER
SLEEVE AS SHOWN
FRONT VIEW
NOTE