Club Car Pioneer 1200, Руководство по техническому обслуживанию

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UNITIZED TRANSAXLE WITH DIFFERENTIAL LOCK Unitized Transaxle Assembly
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 16-35
16
Unitized Transaxle Assembly, Continued:
7.5. Install the intermediate gear assembly into the case as shown (Figure 16-86, Page 16-36). Do
not seat the assembly into the bore, but make sure the output ring gear meshes with the input
drive gear (55) on the synchronizer gear assembly, and with the small gear on the idler shaft (68)
(Figure 16-48, Page 16-20).
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 (55) and the intermediate gear (61) (Figure 16-48, Page 16-20) should be flush
(in the same plane) as shown (Figure 16-87, Page 16-36). Also, the outside surfaces of the idler
gear bearing, the intermediate gear bearing, and the differential gear bearing should be flush
(Figure 16-87, Page 16-36). See following CAUTION.
∆ CAUTION
• If the edges of the input drive gear and intermediate gear are not flush, then the oil guide (40) (Figure
16-48, Page 16-20) 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 16-88, Page 16-36). See fol-
lowing CAUTION.
∆ CAUTION
• Use only Three Bond No. 1215 sealant to seal case. Do not use a substitute.
• If the two sides of the case cannot be easily closed or do not make complete contact, do not force
them together. Check that all internal components are properly seated and then try again.
10. Install and finger tighten the fifteen bolts (28) (Figure 16-40, Page 16-16) that secure the left and right
sides of the case together. Then, in sequence shown, tighten the bolts to 17 ft-lb (23.1 N·m) (Figure
16-89, Page 16-37).
11. Install the differential lock housing to the transaxle.
11.1. Make sure the mating surfaces of the differential lock housing and the transaxle case are clean
and free of oil, grease or residue of any kind.
11.2. Ensure that the alignment pin is installed to the transaxle case (Figure 16-90, Page 16-37).
11.3. Apply a continuous bead of Three Bond No. 1215 (CCI 101928701) around the opening on the
mating surface of the differential lock housing (transaxle side) (Figure 16-90, Page 16-37).
11.4. Rotate the differential lock shaft (95) and insert the cog (104) into the differential lock housing (94)
(Figure 16-74, Page 16-31).
11.5. Using the alignment pin as a guide, position the differential lock housing onto the driver side of the
transaxle case (Figure 16-90, Page 16-37).