UNITIZED TRANSAXLE
Component Disassembly
Page 16-20 2000 FE290 Gasoline Vehicle Maintenance and Service Supplement
16
SHIFTER FORK DISASSEMBLY
1. Push the shift rod (33) out of the shifter fork (34) (Figure 16-42, Page 16-18).
2. Shake the shifter fork to remove the spring (35) and ball (36) (Figure 16-42, Page 16-18).
SYNCHRONIZER GEAR DISASSEMBLY
1. Place a bearing puller wedge attachment (Club Car Part No. 1012812) between the bearing (38) and
spur (governor drive) gear (40) (Figure 16-42, Page 16-18), then press the bearing off the input shaft
as shown (Figure 16-48, Page 16-21). See preceding CAUTION.
2. Pull the spring washer (39), spur gear (40), dowel pin (50), thrust plate (41), input gear assembly (42),
large needle bearing (43), small needle bearing (44), synchronizer ring (45), and thrust plate (41) from
the input shaft (Figure 16-42, Page 16-18).
3. Place a bearing puller wedge attachment (Club Car Part No. 1012812) between the bearing (54) and
input gear assembly (52) (Figure 16-42, Page 16-18), then press the bearing off the input shaft as
shown (Figure 16-49, Page 16-21). See following CAUTION.
4. Pull the spring washer (39), thrust washer (53), input gear assembly (52), two needle bearings (43),
thrust plate (41), and synchronizer ring (45) from the input shaft (Figure 16-42, Page 16-18).
5. Use a small flat-blade screwdriver to remove two synchronizer springs (snap rings) (46), and then slide
the synchronizer clutch hub (49) from the input shaft (51) (Figure 16-42, Page 16-18).
6. Remove the three synchronizer inserts (48) from the synchronizer sleeve (Figure 16-42, Page 16-18).
7. Press the synchronizer sleeve (47) from the input shaft (Figure 16-42, Page 16-18).
INTERMEDIATE GEAR DISASSEMBLY
1. Place bearing puller wedge attachment (Club Car Part No. 1012812) between bearing (38) and shaft/
gear (56) (Figure 16-42, Page 16-18), then press bearing off shaft (Figure 16-50, Page 16-22). See
following
CAUTION.
• MARK PARTS FOR IDENTIFICATION AS THEY ARE DISASSEMBLED. PARTS MUST BE
REASSEMBLED IN THEIR ORIGINAL LOCATIONS AND ORIENTATIONS.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THIS
COULD DAMAGE THE SHAFT.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THIS
COULD DAMAGE THE SHAFT.
• THERE ARE THREE SYNCHRONIZER INSERTS (48) SET INTO SLOTS IN THE SYNCHRONIZER
SLEEVE (47) (FIGURE 16-42, PAGE 16-18). THESE MAY FALL FREE WHEN THE
SYNCHRONIZER CLUTCH HUB (49) IS REMOVED. DO NOT LOSE THESE INSERTS.
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT. THIS
COULD DAMAGE THE SHAFT.
CAUTION
CAUTION
NOTE
CAUTION