Club Car 1997 DS, Maintenance Service Supplement

Page: 71 / 164

Page 63
G
10
they are seated. When all of the assemblies are correctly seated, the outside edges of the input
drive gear (52) and the intermediate gear (58) (See Figure 10-43, Page 53) should be flush (in
the same plane) as shown (Figure 10-80, Page 65). Also, the outside surfaces of the idler gear
bearing, the intermediate gear bearing, and the differential gear bearing should be flush (Figure
10-80, Page 65).
8. Make sure that the mating surfaces of the left and right sides of the casing are clean and free of oil,
grease, or residue of any kind; and that they are not scored or damaged in any way.
9. Then apply a continuous bead of Three Bond No. 1215 sealant to the mating surface, around the com-
plete profile of the right (passenger) side casing (See Figure 10-81, Page 65). See CAUTION below.
10. Install and thread to finger tight the fifteen bolts (27) (Figure 10-36, Page 48) that secure the left and
right sides of the casing together. Then, in sequence shown, tighten the bolts to 15-18 ft.lbs. (20.3/24.4
N-m) (See Figure 10-82, Page 66).
11. Install the axle tubes (75 and 76) on the transaxle casing (Figure 10-6, Page 39).
11.1. Make sure that the mating surfaces of the axle tubes and the transaxle casing are clean and free
of oil, grease, or residue of any kind.
11.2. Apply a continuous bead of Three Bond No. 1215 around the opening on the mating surface of
the right side axle tube as shown (Figure 10-83, Page 66). Then position the axle tube on the
right side of the transaxle casing as shown and install eight mounting bolts (77) with lock washers
(78) (Figure 10-6, Page 39) finger tight. In the sequence shown, tighten the bolts to 33-39 ft.lbs.
(40.7/48.7 N-m) (Figure 10-84, Page 66).
• IF THE EDGES OF THE INPUT DRIVE GEAR AND INTERMEDIATE GEAR ARE NOT FLUSH,
THEN THE OIL GUIDE (37) (FIGURE 10-43, PAGE 53) MAY NOT BE PROPERLY POSITIONED IN
THE BORE.
• USE ONLY THREE BOND NO. 1215 SEALANT TO SEAL CASING. DO NOT USE A SUBSTITUTE.
• IF THE TWO SIDES OF THE CASING CANNOT BE EASILY CLOSED OR DO NOT MAKE COM-
PLETE CONTACT, DO NOT FORCE THEM TOGETHER. CHECK THAT ALL INTERNAL COMPO-
NENTS ARE PROPERLY SEATED AND THEN TRY AGAIN.
FIGURE 10-72 FIGURE 10-73
CAUTION
CAUTION
INSIDE VIEW OF
LEFT SIDE CASTING
EXTERIOR WASHER
COTTER PIN
INTERIOR WASHER
GOVERNOR ARM
INSERT SHIFTER SHAFT FROM
INSIDE OF LEFT SIDE CASING
RETAINING
RING
WASHER