Club Car 1997 DS, Maintenance Service Supplement

Page: 70 / 164

Page 62
10
G
Unitized Transaxle Assembly, Continued:
7.4. Position the shifter fork assembly on the synchronizer gear assembly as shown, and install them
together, bearing end first, into the bore containing the guide (Figure 10-77, Page 64). Do not
seat the assembly, but make sure that the spur gear (40) is meshed with the governor gear (63)
(Figure 10-43, Page 53), and that the shifter lever (14) (Figure 10-36, Page 48) is positioned in
the bracket on the shifter fork (See Figure 10-78, Page 65).
7.5. Install the intermediate gear assembly into the casing as shown (Figure 10-79, Page 65). Do not
seat the assembly into the bore, but make sure that the ring gear meshes with the input drive gear
(52) (Figure 10-43, Page 53) on the synchronizer gear assembly, and with the small gear on the
idler shaft (65) (Figure 10-43, Page 53).
7.6. As a group, while keeping the gears meshed, work all of the gear assemblies into the bores until
FIGURE 10-68 FIGURE 10-69
FIGURE 10-70 FIGURE 10-71
ClubCar
PRESS OIL SEAL
INTO RIGHT
SIDE CASING
INSTALL SHIFTER SHAFT AND
GOVERNOR SHAFT SEALS
INTO THEIR SEATS
POSITION THE GOVERNOR
GEAR SHAFT TOOL
OVER THE SHAFT
BORE IN THE
CASING, THEN INSERT
LONG END OF THE
GOVERNOR GEAR
SHAFT THROUGH TOOL
AND INTO BORE...
...TAP GOVERNOR GEAR
SHAFT THROUGH THE
TOOL AND INTO BORE
IN LEFT SIDE CASING
UNTIL END OF SHAFT
IS EVEN WITH END
OF TOOL.
SHAFT
TOOL
POSITION SLEEVE BETWEEN
FLYWEIGHT BRACKETS
INSERT WASHER AND
GOVERNOR GEAR
(COMPLETE WITH SLEEVE)
ONTO GOVERNOR SHAFT
SLEEVE
PUSH ONTO SHAFT
UNTIL YOU HEAR
THE GOVERNOR
GEAR ASSEMBLY
"SNAP" INTO PLACE