Club Car 2007 XRT 800, Maintenance Service Manual

Page: 497 / 516

TRANSAXLE (TYPE G): ELECTRIC VEHICLE Transaxle Disassembly, Inspection, and Assembly
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual Page 28-9
28
TRANSAXLE ASSEMBLY
CAUT ION
• Do not press against the bearing outer race.
• The housing and all parts must be wiped clean and dry before reassembly.
1. If bearings (13) were removed during disassembly, install new bearings using an arbor press
(Figure 28-5, Page 28-3) .
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figure 28-5, Page 28-3) . Apply a small amount of oil to all thrust plates and to
both ends of the pin.
2.2. Install the hex bolts (33) and output gear (32). Tighten bolts to 58 ft-lb (78.6 N·m).
3. Press a new bearing (18) onto the intermediate gear assembly (Figure 28-5, Page 28-3) .
4. Press new bearing (16) onto input pinion gear (17).
5. Apply grease to the lip of the new oil seal (10) and install the seal using a transaxle pinion seal tool (CCI
P/N 1014161). The lip of the oil seal should face the inside of the transaxle housing. Make sure the seal
is firmly seated.
6. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simulta-
neously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation
(Figure 28-11, Page 28-6) .
7. Install both dowel pins (25) in the transaxle housing (20) (Figure 28-5, Page 28-3) .
8. Install left half of transaxle housing:
8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing.
8.2. Install left half of transaxle housing (20)
(Figure 28-5, Page 28-3) .
8.3. Install eleven bolts (24) in the case housing and tighten to 19 ft-lb (25.7 N·m). Type G transaxles
have no shims or gasket.
8.4. Install axle tube (14 and 35) with bolts (8) (Figure 28-5, Page 28-3) . Tighten the bolts to 37 ft-lb
(50.2 N·m).
9. Install the brake assemblies as instructed. See Brake Cluster Installation on page 6-9.
Figure 28-15 Differential Pin Figure 28-16 Left Differential
DIFFERENTIAL
PIN
DIFFERENTIAL
GEAR
LEFT
DIFFERENTIAL
GEAR
CASE
3
4
1
2