© December 2007
7-10
Section 7 - Rear Wheels,
Rear Suspension and Axle Assembly
2007 Eagle Electric Golf Car Service Manual
Figure 7-26. Installing Differential Case Assembly
Figure 7-27. Installing Cup Plugs
Figure 7-28. Axle Components
9. Position differential case assembly (4) with
fl
anged side trun-
nion face down on work surface. Align output gear (5) mount-
ing holes with differential case. Install four bolts (6) and nuts
(7). Bolts should be installed from differential
fl
ange side.
Torque nuts to 35-45 ft. lbs. (47-61 Nm). See Figure 7-24.
10. Differential bearings (8) can be installed on differential case
(4) before or after installing ring gear. Use care not to damage
differential bearings or
fi
nal gear (5) when installing the op-
posite component.
11. Position housing (1) with opening facing up. Insert differential
case, output gear (5) and bearing (8) assembly into housing.
Make sure teeth of gear (5) mesh with teeth of small gear on
intermediate shaft (9) and that both turn freely. See Figure 7-
25.
NOTICE
Bearing caps are marked for identi
fi
cation. Letters or num-
bers are stamped in horizontal and vertical position. When
reassembling, install caps back in their original positions,
using these stamps as a guide.
12. Install differential bearing caps (2) with bolts (3). Torque bolts
to 35-45 ft. lbs. (47-61 Nm).
13. Place a small bead of RTV (non-acidic) silicone sealant to
fl
ange of cover plate (18). Sealant should be applied to inside
of cover plate mounting holes (Figure 7-26).
14. Install cover plate (18) with ten bolts (20). Torque bolts to 16-
24 ft. lbs. (21.5-32.5 Nm).
15. Install new intermediate cup plug (17) to both sides of housing
(1). Use Loctite Safety Solvent #75559 to clean bores, then
apply Loctite RC 609 to housing bores. Cup plugs can be
installed by using a properly sized driver and hammer. Cup
plugs should be
fi
rmly seated against snap rings (16). See
Figure 7-27.
16. With properly sized seal driver, install shaft oil seals (24).
Press seals to depth of 1.125” (28.5 m). See Figure 7-28.
17. Install inner snap ring (25) to both right and left tubes. See
Figure 7-29).
18. Press bearings (26) onto axle shafts (22). Bearing should
seat on shoulder. Use appropriate driver to install bearings.
See Figure 7-30.
19. Coat lip of seal (24) with SAE 30 oil before inserting axle shaft
(22). Insert axle shaft assemblies into tubes. Using a properly
sized bearing driver, tap axle shaft assembly until it is seated
fi
rmly against inner snap ring (25).
Shaft may have to be rotated to engage differential splines
during installation.
20. Install outer snap ring (25) in each tube (Figure 7-31).
21. Remove
fi
ll plug (19) in cover plate (18). Fill axle assembly
with 12 ounces (360 ml) of Light Weight Gear Lubricant, SAE
30.
Install
fi
ll plug. If it is a threaded plug, torque to 25-40 ft. lbs.
(6-14 Nm).
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