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12. Replace the thrust washers if worn. If the pump housing
assembly is replaced, replace the thrust washers as well.
NOTE: If any of the gears are worn and require replacement,
check the grease in the gear housing for metal
particles or shavings. Remove the contaminated
grease. Replace the grease that has been removed
with fresh Lubriplate GR-132 grease.
13. Coat each of the thrust balls with a generous amount of
grease. Install the thrust balls — one in the gear housing bore
and one in the pump housing bore.
14. Coat the gear assembly with fresh Lubriplate GR-132 grease.
Insert the gear assembly into the bore in the pump housing,
pinion end first.
15. Generously coat both faces of each of the crankshaft thrust
washers with grease.
16. Place the thick thrust washer onto the crankshaft up against
the gear hub. Next, place the thin thrust washer up against
the thick washer on the crankshaft.
17. Place the housing gasket over the gear housing dowel pins.
18. Carefully place the pump housing assembly in front of the
gear housing assembly, lining up the gear housing dowel pins
with their corresponding holes in the pump housing. Slide
the pump housing onto the gear housing until there is no gap
between the housings and gasket.
ImPORTANT: Do not force the pump housing and gear housing
together.
19. Locate the four socket screws and lock washers that secure
the pump housing to the gear housing. The longer screws
(2.25”) are fastened into the top internal holes. The shorter
screws (2”) are fastened into the bottom external bosses.
20. Using a 1/4” hex wrench, snug and tighten the socket screws
in a crossing pattern. Torque to 200–230 in.-lbs.
21. If the slider, slider housing, and fluid section were removed,
reinstall by following the steps in the “Replacing the Slider and
Slider Housing” procedure in this section.
22. Position the front cover over the pump housing. Secure the
front cover using the four front cover screws.
23. Using a 7/8” open-end wrench, attach the fluid hose to the
fitting on the back of the fluid section. Tighten securely.
Servicing the clutch Assembly
NOTE: When replacing the clutch armature, the clutch hub
and clutch rotor must be replaced also. This will
allow for even wear and maximum life on clutch
parts.
Removing/Replacing the clutch Hub and Armature Assembly
1. Perform the Pressure Relief Procedure.
2. Using a 7/8” open-end wrench, loosen and remove the fluid
hose from the fitting on the back of the fluid section.
3. Hold the transducer tube with a pliers to prevent it from
rotating and turn the transducer nut counterclockwise using
a 3/4” open-end wrench. When the nut disengages the filter
housing, carefully remove the transducer from the filter
housing.
4. Locate the wire that exits the rear of the electronic pressure
control (EPC) housing and connects to the wire harness on the
engine. Disconnect this wire from its connector at the engine
wire harness.
5. Using a 1/2” wrench, remove the four hex screws and lock
washers that secure the clutch housing to the gear housing.
6. Using a 9/16” socket, remove the two hex screws that secure
the gear housing to the cart.
7. Slide the pump and gear housings away from the engine to
disengage them from the clutch housing.
Clutch Armature
Clutch Hub
Taper Lock Bushing
Gear
Housing
Pump
Housing
Lock
Washer
Clutch
Housing
Clutch Housing
Hex Screw
Engine Shaft
Gear Housing
Hex Screw
Set Screw
8. Locate the clutch hub and armature assembly on the end
of the engine shaft. Note the two set screws as well as the
unused, threaded hole in the taper lock bushing at the center
of the clutch hub.
9. Using an 1/8” hex wrench, remove the two set screws from the
taper lock bushing
10. Thread one of the set screws into the unused, threaded hole
on the taper lock bushing. As the screw tightens, the bushing
will loosen. Once the bushing has loosened enough, slide the
clutch hub and armature assembly off the engine shaft.
Clutch
Hub
Flat
Surface
Set-Up
Tool
Clutch
Armature
11. Before replacing the clutch
hub and armature assembly
the proper “set back” must be
created. Using the Titan hub
set-up tool (P/N 0509925),
create a “set back” of 0.20”
between the friction surface
of the clutch armature and the
forward face of the clutch hub.
NOTE: A new clutch hub and
armature assembly will come
pre-assembled, but the “set
back” will not be correct. The
“set back” must still be created
using the hub set-up tool.
0.20"
12. Line up the three holes in the taper lock bushing with the
three holes in the clutch hub and insert the bushing into the
center of the clutch hub.
13. Line up the key on the taper lock bushing with the keyway on
the engine shaft and slide the assembly onto the shaft with
the holes facing out.
Clutch
Housing
0.20"
Engine
Set
Screw
Straight
Edge
Taper
Lock
Bushing
14. Apply blue Loctite to the
two set screws and insert the
screws into the taper lock
bushing. Tighten the set
screws only two turns at this
time.
15. Line up the forward face of
the clutch hub with the front
face of the clutch housing.
Using an 1/8” hex wrench,
alternately tighten the set
screws into the taper lock
bushing. Torque to 65–75 in-lbs.
NOTE: To ensure the clutch hub and the clutch housing are
aligned, hold a straight edge across the face of the
clutch housing and then hold the clutch hub against
the back of the straight edge while tightening the
two set screws into the taper lock bushing.
16. Make sure the friction surface of the clutch armature is clean
and free from oil or grease.
