Club Car Carryall 300 2021, Maintenance And Service Manual

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17
Transaxle Disassembly, Inspection, and Assembly ELECTRIC VEHICLE - TRANSAXLE
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 17-5,
Page 17-3) .
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figure 17-5, Page 17-3) . 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 17-5, Page 17-3) .
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. 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 17-11, Page 17-7) .
7. Install both dowel pins (25) in the transaxle housing (20) (Figure 17-5, Page 17-3) .
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 17-5, Page 17-3) .
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 17-5, Page 17-3) . Tighten the bolts to 37 ft·lb (50.2 N·m).
9. Install the brake assemblies as instructed. See Wheel Brake Assemblies Section.
10. Apply a small amount of grease to the lip of the oil seal (15) (Figure 17-5, Page 17-3) . See following CAUTION.
CAUTION
• Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to
installing the axle shaft to prevent oil from coming in contact with brakes.
11. Install the rear axle onto the transaxle.
11.1. Insert the splined end of the axle shaft into the axle tube. Be careful not to damage the seal on the inside of
the axle tube hub. Advance the shaft through to the bearing on the shaft, and rotate it to align the shaft
splines with the splined bore of the differential gear. Continue advancing the shaft until the bearing on the
axle is firmly seated within the axle tube hub seat.
11.2. Using 90° internal snap ring pliers (0.090 tip), attach the internal retaining ring into the axle tube hub so that
it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube
hub
(Figure 17-5, Page 17-3) .
11.3. Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four or five
locations to ensure it is properly seated. See following WARNING .
Page 17-10 2021 Carryall 300 Maintenance and Service Manual