UNITIZED TRANSAXLE
Unitized Transaxle Assembly
Page 16-30 2001 Pioneer 900 Gasoline Vehicle Maintenance and Service Manual
16
Unitized Transaxle Assembly, Continued:
7.5. Install the intermediate gear assembly into the case as shown (Figure 16-77, Page 16-33). Do
not seat the assembly into the bore, but make sure the output ring gear meshes with the input
drive gear (52) (Figure 16-41, Page 16-18) on the synchronizer gear assembly, and with the
small gear on the idler shaft (65) (Figure 16-41, Page 16-18).
7.6. As a group and while keeping the gears meshed, work all of the gear assemblies into the bores
until 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) (Figure 16-41, Page 16-18) should be flush
(in the same plane) as shown (Figure 16-78, Page 16-34). Also, the outside surfaces of the idler
gear bearing, the intermediate gear bearing, and the differential gear bearing should be flush
(Figure 16-78, Page 16-34). See following CAUTION.
∆ CAUTION
• If the edges of the input drive gear and intermediate gear are not flush, then the oil guide (37) (Figure
16-41, Page 16-18) may not be properly positioned in the bore.
8. Make sure the mating surfaces of the left and right sides of the case are clean and free of oil, grease, or
residue of any kind, and they are not scratched or damaged in any way.
9. Apply a continuous bead of Three Bond No. 1215 (CCI 101928701) sealant to the mating surface,
around the complete profile of the right (passenger side) case (Figure 16-79, Page 16-34). See fol-
lowing CAUTION.
Figure 16-66 Install Seals
Figure 16-67 Governor Gear Shaft
ClubCar
Press oil seal
into right side
case.
Install shifter shaft and
governor shaft seals
into their seats.
Position the governor
gear shaft tool
(CCI 101933101)
over the shaft bore
in the case, then insert
long end of the governor
gear shaft through tool
and into bore...
...tap governor gear
shaft through the
tool and into bore
in left side of case
until end of shaft
is even with end
of tool.
SHAFT
TOOL