Club Car CARRYALL 252 2007, Maintenance And Service Manual

Page: 515 / 536

TRANSAXLE (TYPE G): ELECTRIC VEHICLES Transaxle Disassembly, Inspection, and Assembly
28
8.5. Remove the idler gears (1 and 2) and thrust plates (3 and 4) (Figure 28-16, Page 28-9) .
1
5
6
26
2
8
7
3
4
Figure 28-15 Differential Pin Figure 28-16 Left Differential
8.6. Remove the differential gears (5 and 6) and thrust plates (7 and 8).
8.7. Inspect the bearings (13) of the differential case (26) and replace them if they are damaged (Figure 28-5,
Page 28-3) . To remove them, press them off. See following CAUTION.
CAUTION
• Do not reuse bearings after removing them. Replace bearings with new ones.
9. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE.
NOTE: Damaged or worn gears should be replaced as sets.
TRANSAXLE ASSEMBLY
CAUTION
• 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 simultaneously. 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) .
2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual Page 28-9