Club Car 1997 DS, Maintenance Service Supplement

Page: 68 / 164

Page 60
10
G
Differential Gear Case Assembly, Continued:
4. Position the other thrust plate (85) and idler gear (89) (Figure 10-6, Page 39) in the carrier case as
shown (Figure 10-64), and then continue to drive the pin through them and the wall of the carrier case
until the ends of the pin are flush with the sides of the carrier case (Figure 10-64).
5. Install the thrust plate (86) and idler gear (90) into the carrier case cover (87) (Figure 10-6, Page 39)
as shown (Figure 10-65). Then, while holding the thrust plate and idler gear in place, position the car-
rier case cover on the carrier case as shown (Figure 10-65).
6. Position the ring gear (81) (Figure 10-6, Page 39) on the carrier case, visually aligning the dowel hole
in the ring gear with the pin in the carrier. Then, using a wooden mallet, tap the ring gear into place on
the dowel pin as shown (Figure 10-66).
7. Apply Loctite® 277 on the threads of the eight mounting bolts and install them through the ring gear,
carrier case, and into the carrier case cover. Then tighten the bolts to 16-20 ft.lbs. (21.7/27.1 N-m) in
the sequence shown (Figure 10-67).
GOVERNOR GEAR ASSEMBLY
The governor gear is not assembled independently from the unitized transaxle casing. The gear shaft is
installed into the casing and then the rest of the assembly is installed on the shaft. Proceed with unitized
transaxle assembly.
UNITIZED TRANSAXLE ASSEMBLY
1. Make sure that both parts of the casing are clean and free of any contaminants. Make sure that the
machined mating surfaces are free of residue, and are not scored or damaged in any way.
2. Press two new oil seals (13 and 22) (Figure 10-36, Page 48) into the left (driver) side casing, and one
new oil seal (55) (Figure 10-43, Page 53) into the right (passenger) side casing (See Figure 10-68,
Page 62).
FIGURE 10-64 FIGURE 10-65
POSITION SECOND
THRUST PLATE AND
SECOND IDLER GEAR
IN DIFFERENTIAL
GEAR CARRIER
CASE ...
...THEN CONTINUE
TAPPING PIN THROUGH
SECOND IDLER GEAR AND
THRUST PLATE UNTIL PIN
IS FLUSH WITH OUTSIDE
OF HOUSING
POSITION
DIFFERENTIAL
GEAR AND
THRUST PLATE
IN CARRIER
CASE COVER ...
...THEN, WHILE
HOLDING GEAR
AND THRUST PLATE
IN POSITION, ROTATE
COVER AND POSITION
IT ON CARRIER CASE