© December 2007
7-9
2007 Eagle Electric Golf Car Service Manual
Section 7 - Rear Wheels,
Rear Suspension and Axle Assembly
Figure 7-22. Removing O-rings from
Intermediate Shaft & Gear
21. Clean the axle housing and carrier cover (18) with lint-free
rags. Remove all traces of old silicone sealant from sealing
surface of cover and housing.
Assembling Rear Axle
All callout numbers in steps refer to Figure 7-6.
1. Prior to installing, wipe new O-rings with SAE 30 weight oil.
Install one O-ring (14) into outer input shaft (12) bearing bore.
Install two O-rings (14) into intermediate shaft (9) bearing
bores and two O-rings (10) onto intermediate shaft and gear
assembly.
2. Press inner and outer bearings (13, 15) on input shaft (12)
until seated against bearing shoulders. See Figure 7-23.
3. Install new O-ring (14) into bearing bore of input shaft (12).
NOTICE
Input shaft assembly must be supported by hand as not to
damage gear teeth. Use care if using a hammer to coax shaft
and gear into correct position. Use care if using a hammer to
coax shaft and gear into correct position.
4. Install input shaft (12). Bearings (13, 15) and shaft should
slide easily into housing. If resistance is encountered, use a
plastic or leather mallet to tap shaft into position. See Figure
7-20.
5. Install outer snap ring (16) at input shaft bore. See Figure 7-
21.
6. After O-rings (10) are installed on shaft (9) and housing (1),
install intermediate shaft and gear assembly (9) through bot-
tom opening in housing.
NOTICE
Small end of intermediate shaft and gear assembly must be
tilted toward bottom opening until bearing trunnion visually
engages intermediate bores.
7. Align both bearing trunnions with intermediate bore. Continue
supporting intermediate shaft and gear assembly with one
hand and insert the
fl
anged side bearing (11) into opening.
Figure 7-23. Installing Bearings on Input Shaft
Figure 7-24. Torquing Differential Case Nuts
Figure 7-25. Installing Differential Case Assembly
To seat the bearing past the O-ring, a leather or plastic mallet
may be required.
NOTICE
Intermediate shaft assembly must be supported by hand as
not to damage gear teeth. Use care if using a hammer to coax
shaft and gear into correct position.
8. After
fl
anged side bearing is seated past snap ring groove, in-
stall snap ring (16). Repeat procedure for opposite side bear-
ing and snap ring.
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