section 16–transaxle

section 16–transaxle
16
SECTION 16–TRANSAXLE
DANGER
• BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY.
VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL
FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES.
• USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR
BATTERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
• BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. ANTIDOTES:
- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN IMMEDIATELY.
- INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OF
MAGNESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
WARNING
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY
AND HEED ALL WARNING STATEMENTS IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD/REVERSE HANDLE IN THE NEUTRAL POSITION,
AND REMOVE KEY BEFORE SERVICING THE VEHICLE.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
• USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CONNECTIONS.
• LIFT ONLY ONE END OF THE VEHICLE AT A TIME. BEFORE LIFTING, UNLOAD THE CARGO
BED, LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A
SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454
KG.) MINIMUM LIFTING CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN
RAISED POSITION. ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY
TO SUPPORT THE VEHICLE.
• TO AVOID UNINTENTIONALLY STARTING VEHICLE, DISCONNECT BATTERIES AS SHOWN IN
SECTION 11, FIGURE 11-1, PAGE 11-2 AND DISCHARGE THE CONTROLLER AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE
REVERSE POSITION.
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
GENERAL INFORMATION
There are two types of transaxles used in the manufacture of the electric vehicle. The different transaxles are identified by the orientation of the gear case bolt heads. The Type G transaxle has gear case bolt heads oriented toward
the passenger side of the vehicle. The Type K transaxle has gear case bolt heads oriented toward the driver side of
the vehicle. Please note that parts used in these transaxles are not interchangeable with one another. Service and
repair procedures specific to each transaxle are noted throughout this section.
LUBRICATION
There are two plugs located on the lower half of the transaxle housing. The upper plug (as viewed when the vehicle is on a level surface), is used as a lubricant level indicator. When the vehicle is parked on a level surface, the
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
Page 16-1
16
TRANSAXLE
Axle Bearing and Shaft
Lubrication, Continued:
lubricant level should be even with the bottom of the hole. The lower plug is for draining the lubricant. When
draining the lubricant, the upper plug should be removed so the lubricant will drain faster. Be sure the drain plug
is reinstalled before filling.
NOTE
• RECYCLE OR DISPOSE OF USED OIL OR LUBRICANT IN ACCORDANCE WITH LOCAL, STATE
AND FEDERAL REGULATIONS.
AXLE BEARING AND SHAFT
Read DANGER and WARNING on page 16-1.
AXLE SHAFT
Axle Shaft and Oil Seal Removal
1. Place chocks at the front wheels. Loosen lug nuts on rear wheels and lift the rear of the vehicle with a
chain hoist or floor jack. Place jackstands under the axle tubes to support the vehicle.
2. Remove the rear wheel and brake drum. See Section 6–Wheel Brake Assemblies and Section 8–
Wheels and Tires in the appropriate Maintenance and Service Manual.
3. Using 90° internal snap ring pliers, remove the internal retaining ring (6) from the axle tube (Figures
16-3 or 16-4, Pages 16-3 or 16-4). See also Figure 16-1, Page 16-2.
4. Remove the axle, retaining ring, and bearing assembly by pulling the axle straight out of the housing.
Figure 16-1 Axle Tube
Figure 16-2 Rolling Wedge Bar
5. Use a 16 in. (40 cm) rolling wedge bar (Figure 16-2, Page 16-2) to remove oil seal. Insert wedge bar
underneath the seal lip and pry out oil seal (17) (Figure 16-5, Page 16-5). See following CAUTION.
CAUTION
• DO NOT SCAR OR DAMAGE THE INSIDE SURFACES OF THE TUBE WHEN REMOVING THE
OIL SEAL. A DAMAGED TUBE MIGHT HAVE TO BE REPLACED.
6. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated
against the shoulder on the axle shaft.
7. Inspect bearing (5) (Figure 16-3, Page 16-3 or Figure 16-4, Page 16-4). If the bearing in a Type K transaxle is worn or damaged, replace bearing. If the bearing in a Type G transaxle is worn or damaged, see
NOTE at Axle Bearing on Page 16-5.
Page 16-2 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
TRANSAXLE
Axle Bearing and Shaft
REFERENCE
MOTOR—
SECTION 15
43
42
12
11
13
10
9
8
3
1
15
7
17
24
16
18
4
26
19
5
6
18
18
23
25
TYPICAL
2 PLACES
22
21
30
20
28
27
29
6
14
5
41
31
4
37
17
38
40
7
37
14
33
34
34
36
2
8
35
9
32
39
15
3
Figure 16-3 Transaxle - Type K
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-3
16
16
TRANSAXLE
Axle Bearing and Shaft
REFERENCE
MOTOR—
SECTION 15
12
38
37
11
10
9
8
3
1
24
7
36
15
20
16
17
14
4
5
6
16
16
19
18
23
21
22
25
6
32
5
34
4
36
26
33
13
13
15
35
7
30
31
30
28
2
8
29
27
27
9
36
Figure 16-4 Transaxle - Type G
Page 16-4 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
3
TRANSAXLE
Axle Bearing and Shaft
Figure 16-5 Seal Lip
AXLE BEARING
NOTE
• DO NOT REMOVE AXLE BEARING FROM A TYPE G TRANSAXLE. IF BEARING IS WORN OR
DAMAGED, THE ENTIRE AXLE ASSEMBLY (1 OR 2) MUST BE REPLACED (FIGURE 16-4, PAGE 16-4).
Axle Bearing Removal (Type K Transaxle Only)
1. Remove the retaining ring (7) from the axle shaft (Figure 16-3, Page 16-3).
2. Place a bearing puller wedge attachment (Club Car Part No. 1012812) on the axle shaft between the
wheel mounting flange and the bearing.
3. Press bearing (5) and collar (4) off together (Figure 16-6, Page 16-5).
CAUTION
• DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT.
THIS COULD DAMAGE THE AXLE SHAFT WHEN PRESSING OFF THE BEARING AND COLLAR.
NOTE
• IT MAY BE NECESSARY TO HEAT THE COLLAR BEFORE THE COLLAR CAN BE REMOVED.
BEARING
PULLER
WEDGE
ATTACHMENT
PRESS RAM
AXLE SEAL
TOOL
4
5
AXLE SEAL
Figure 16-6 Bearing and Collar
Figure 16-7 Axle Seal Tool
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-5
16
16
TRANSAXLE
Axle Bearing and Shaft
Axle Bearing Installation (Type K Transaxles Only)
1. If removed, place retaining ring (6) on axle shaft (1 or 2) (Figure 16-3, Page 16-3). The retaining ring
will be loose on the axle shaft until it is installed into the axle tube.
2. Apply two drops of Loctite® 271 to the inside of the collar.
CAUTION
• APPLY LOCTITE® 271 TO INSIDE OF COLLAR ONLY, NOT TO THE SHAFT, SO THE LOCTITE
WILL BE PUSHED AWAY FROM THE BEARING AS THE COLLAR AND BEARING ARE PRESSED
ON. IF LOCTITE GETS ON OR IN THE BEARING, THE BEARING MUST BE REPLACED.
• THE COLLAR SHOULD BE REMOVED NO MORE THAN TWO TIMES. IF A BEARING IS
REMOVED A THIRD TIME, THE SHAFT AND COLLAR WILL NOT GIVE A PROPER FIT.
3. Place the bearing and the collar on the shaft (note, this is a sealed bearing). See following CAUTION.
CAUTION
• IF THE BEARING WAS REMOVED FROM THE SHAFT, REPLACE BEARING WITH A NEW ONE.
4. Place the bearing puller wedge attachment against the collar and press on both the bearing and collar.
See CAUTION on page 16-5.
5. Install retaining ring (7) into the groove on the axle shaft (Figure 16-3, Page 16-3).
Axle Shaft and Oil Seal Installation
1. Clean bearing and seal seats in the axle tube (16 or 40) (Figure 16-3, Page 16-3) or (14 or 35) (Figure
16-4, Page 16-4).
2. Place a new seal (17) (Figure 16-3) or (15) (Figure 16-4) in the axle tube with the seal lip facing away from
the bearing. Use an axle seal tool (Club Car Part No. 1014162) and mallet to tap it in until it seats firmly in
position (Figure 16-7, Page 16-5). A hydraulic press may also be used with the axle seal tool.
3. Clean the shaft splines and then insert the shaft, splined end first, through the seal and into the axle
tube. Be careful not to damage the seal. Then advance the shaft through the inner bearing and rotate it
to align the shaft splines with the splined bore of the differential side gear. Continue advancing the shaft
until the bearing seats against the axle tube shoulder.
4. Using snap ring pliers, install retaining ring (6) inside axle tube (Figure 16-3 or 16-4, Pages 16-3 or 16-4).
See following NOTE.
NOTE
• TYPE G TRANSAXLES: IF RETAINING RING (6) MUST BE REPLACED, THE ENTIRE AXLE SHAFT
ASSEMBLY (1 OR 2) MUST BE REPLACED (FIGURE 16-4, PAGE 16-4).
5. Place a 1/4 in. to 3/8 in. (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four to
five locations around the retaining ring to ensure it is properly seated. See following WARNING.
WARNING
• BE SURE THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE. IF THE RING IS NOT
PROPERLY INSTALLED, THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND
DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS. LOSS OF VEHICLE CONTROL
COULD RESULT, CAUSING SEVERE PERSONAL INJURY.
Page 16-6 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
TRANSAXLE
Transaxle
TRANSAXLE
Read DANGER and WARNING on page 16-1.
TRANSAXLE REMOVAL
1. Place chocks at the front wheels and slightly loosen the lug nuts on both rear wheels.
2. Place floor jack under transaxle and raise rear of vehicle (Figure 16-8, Page 16-7) then place jackstands
under frame cross-member between the spring mount and the side stringer, just forward of each rear wheel.
Lower the vehicle to let the jackstands support the vehicle.
3. Remove the rear wheels, then thread one lug nut onto a stud on each rear hub. This will keep the brake
drums on the hubs.
4. Remove the cotter pins (1), brake cable clevis pins (2), and cable retaining E-clips (3). Disconnect the
brake cables (4) (Figure 16-9, Page 16-7).
5. Disconnect the shock absorbers from their lower mounts (Figure 16-10, Page 16-7).
2
4
3
Figure 16-8 Support Vehicle on Jackstands
1
Figure 16-9 Disconnect Brakes
REMOVE BOLTS, THEN
ROTATE SHACKLES
UP AND AWAY
FROM SPRING
DISCONNECT SHOCK
ABSORBERS FROM
LOWER MOUNTS
Figure 16-10 Disconnect Shocks
Figure 16-11 Shackles
6. Disconnect the four motor wires. Use two wrenches to prevent the studs from turning.
7. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so
they are clear of springs (Figure 16-11, Page 16-7).
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-7
16
16
TRANSAXLE
Transaxle
Transaxle Removal, Continued:
8. If a chain hoist was used to raise the vehicle, lift the vehicle high enough to permit easy access and
clearance for removal of the motor. If a floor jack was used to raise the vehicle, lower the transaxle
enough to permit easy access and clearance for removal of the motor.
9. Remove the three motor mounting bolts (Figure 16-13, Page 16-8), and the motor positioning bolt
(Figure 16-14, Page 16-8) mounting the motor to the transaxle. See following WARNING.
WARNING
• DO NOT POSITION FINGERS UNDER MOTOR WHEN SLIDING OFF INPUT SHAFT IN STEP 9.
FINGERS MAY GET PINCHED WHEN MOTOR DISENGAGES.
MOTOR MOUNTING
BOLTS
REST LEAF SPRINGS ON FLOOR
THEN REMOVE U-BOLTS
INPUT
PINION
GEAR
INTERMEDIATE
GEAR ASSEMBLY
Figure 16-12 Leaf Springs
DIFFERENTIAL
GEAR CASE
Figure 16-13 Motor Mounting Bolts
INSTALL MOTOR ON TRANSAXLE,
ALIGN AND INSTALL POSITIONING BOLT
Figure 16-14 Motor Positioning Bolt
10. Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor
spline becomes disengaged from the input shaft, then lift motor out. See preceding WARNING.
11. If a floorjack was used, pull floorjack from beneath the transaxle and allow the springs to rest on the floor.
12. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 16-12, Page 16-8).
13. Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle
to the rear and out of the vehicle.
14. If removal of the brake assemblies is required, see Section 6–Wheel Brake Assemblies in the Maintenance and Service Manual.
Page 16-8 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
TRANSAXLE
Transaxle Disassembly, Inspection and Assembly
TRANSAXLE DISASSEMBLY, INSPECTION AND ASSEMBLY
Read DANGER and WARNING on page 16-1.
TRANSAXLE DISASSEMBLY AND INSPECTION
1. To detach axle tubes (16 and 40) (Figure 16-3, Page 16-3) or (14 and 35) (Figure 16-4, Page 16-4)
from the transaxle housing, remove the bolts and lock washers (8 and 9) (Figure 16-3 or 16-4).
NOTE
• TYPE K TRANSAXLES ONLY: SHIMS ARE LOCATED BETWEEN AXLE TUBE AND
DIFFERENTIAL CASE BEARING. DO NOT DAMAGE SHIMS. IF SHIMS ARE REMOVED, SET
THEM ASIDE FOR REINSTALLATION.
2. Remove 10 bolts (26) (Figure 16-3, Page 16-3) or 11 bolts, (24) (Figure 16-4, Page 16-4) that hold housing together.
3. Pull the halves of the housing apart. If necessary, tap lightly on the spline of the input pinion.
CAUTION
• TO PREVENT DAMAGE TO THE HOUSING MATING SEAL SURFACES, USE CAUTION WHEN
SEPARATING HALVES.
4. Remove input pinion gear by pulling gear (19) (Figure 16-3, Page 16-3) or (17) (Figure 16-4, Page 16-4)
out while rocking intermediate gear assembly. Lift intermediate gear assembly and differential gear case unit
out simultaneously.
CAUTION
• DO NOT DAMAGE GEARS. USE EXTREME CARE WHEN HANDLING THEM.
REMOVE KEY
PRESS RAM
ARBOR
Figure 16-15 Intermediate Gear Assembly
Figure 16-16 Remove Key
5. Use a bearing puller or arbor press to remove bearings (18) (Figure 16-3, Page 16-3) or (16) (Figure
16-4, Page 16-4) from the input pinion gear. If the oil seal (10) is damaged, replace it (Figures 16-3 or
16-4, Pages 16-3 or 16-4). See also Figure 16-15, Page 16-9. See following CAUTION.
CAUTION
• DO NOT REUSE BEARINGS AFTER REMOVING THEM. REPLACE BEARINGS WITH NEW ONES.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-9
16
16
TRANSAXLE
Transaxle Disassembly, Inspection and Assembly
Transaxle Disassembly and Inspection, Continued:
6. To disassemble the intermediate gear assembly, press off together the bearing (18) (Figure 16-3, Page
16-3) or (16) (Figure 16-4, Page 16-4) and the gear (23) (Figure 16-3, Page 16-3) or (19) (Figure 164, Page 16-4). See also Figure 16-15, Page 16-9.
7. Type K transaxles: Remove key (22) (Figure 16-3, Page 16-3). See also Figure 16-16, Page 16-9.
8. Press the bearing (20) (Figure 16-3, Page 16-3) or (18) (Figure 16-4, Page 16-4) off the intermediate
gear assembly.
9. Disassemble the differential gear case:
DOWEL PIN
LOCK PLATE
TO SEPARATE HOUSING,
IT MAY BE NECESSARY TO
INSERT HEX HEAD BOLTS
INTO HOUSING AND
TAP LIGHTLY
Figure 16-17 Lock Plate (Type K Only)
Figure 16-18 Separate Housing
9.1. Type K transaxles: Bend the bolt lock plates (29) down onto the ring gear (30) (Figure 16-3,
Page 16-3). See also Figure 16-17, Page 16-10.
9.2. Remove eight hex bolts (28) (Figure 16-3, Page 16-3) or four hex bolts, (33) (Figure 16-4, Page 16-4),
that secure the ring gear to the differential case.
9.3. Remove the ring gear. Retain dowel pin from between ring gear and differential case for reassembly.
9.4. Separate the differential gear case housing. If necessary, reinstall two of the hex bolts (removed
previously in step 9.2.) into the differential gear unit and, while holding the unit slightly above the
work area, lightly tap the bolt heads (Figure 16-18, Page 16-10). Remove the two bolts.
9.5. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figures 16-3 or 16-4, Pages 16-3 or 16-4). See also Figure 16-19, Page 16-10.
SIDE
GEAR
DIFFERENTIAL
PIN
4
THRUST
WASHER
2
1
PUSH
DIFFERENTIAL
PIN THROUGH
DIFFERENTIAL
GEAR CASE
Figure 16-19 Differential Pin
3
LEFT
DIFFERENTIAL
GEAR
CASE
Figure 16-20 Left Differential
Page 16-10 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
TRANSAXLE
Transaxle Disassembly, Inspection and Assembly
9.6. Remove the idler gears and thrust plates (38 and 35), (Figure 16-3, Page 16-3) or (29 and 28)
Figure 16-4, Page 16-4).
9.7. Remove the differential gears and thrust plates (34 and 37) (Figure 16-3, Page 16-3) or (30 and
27) (Figure 16-4, Page 16-4). See also Figure 16-20, Page 16-10.
9.8. Inspect the bearings (14) (Figure 16-3, Page 16-3) or (13) (Figure 16-4, Page 16-4) of the differential
case and replace them if they are damaged. To remove them, press them off. See CAUTION at bottom
of page 16-9.
10. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE.
NOTE
• DAMAGED OR WORN GEARS SHOULD BE REPLACED AS SETS.
TRANSAXLE ASSEMBLY
CAUTION
• DO NOT PRESS AGAINST THE BEARING OUTER RACE.
• TYPE K TRANSAXLES: GASKET (13) FACES OF THE HOUSING MUST BE CLEAN AND
SMOOTH. USE ONLY A NEW GASKET THAT IS NOT TORN OR DAMAGED. THE GASKET MUST
LIE FLAT AGAINST THE HOUSING FACES (FIGURE 16-3, PAGE 16-3).
• THE HOUSING AND ALL PARTS MUST BE WIPED CLEAN AND DRY BEFORE REASSEMBLY.
1. If bearings (14) (Figure 16-3, Page 16-3) or (13) (Figure 16-4, Page 16-4) were removed during disassembly, install new bearings using an arbor press.
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figures 16-3 or 16-4, Pages 16-3 or 16-4). Apply a small amount of oil to all
thrust plates and to both ends of the pin.
• Type K transaxles:
2.2. While aligning the dowel pin, assemble the two halves of the differential gear case (33 and 36)
and reinstall the output gear (30) (Figure 16-3, Page 16-3).
2.3. Install eight hex bolts (28) and the bolt lock plates (29) (Figure 16-3, Page 16-3). Tighten the bolts
to 18 ft.lb (24 N-m).
2.4. Bend the edges of the bolt locking tabs securely against the flats of the bolt heads to prevent the
bolts from loosening and possibly causing damage (Figure 16-17, Page 16-10).
2.5. If the large gear (23) was removed from the intermediate gear, insert key (22) into keyway in the shaft
and then press the large gear and the bearing (18) onto the shaft. Be sure the key is properly positioned
in the keyway before attempting to press on the large gear and bearing (Figure 16-3, Page 16-3).
• Type G transaxles:
2.6. Install four hex bolts (33) and output gear (32). Tighten bolts to 51 ft.lb (69 N-m) (Figure 16-4,
Page 16-4).
• All transaxles:
3. Press a new bearing (20) (Figure 16-3, Page 16-3) or (18) (Figure 16-4, Page 16-4) onto the intermediate gear assembly.
4. Press new bearing (18) (Figure 16-3, Page 16-3) or (16) (Figure 16-4, Page 16-4) onto input pinion gear.
5. Apply grease to the lip of the new oil seal (10) (Figures 16-3 or 16-4, Pages 16-3 or 16-4) and install
the seal using a transaxle pinion seal tool (Club Car Part No. 1014161). The lip of the oil seal should
face the inside of the transaxle housing. Make sure the seal is firmly seated.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-11
16
16
TRANSAXLE
Transaxle Disassembly, Inspection and Assembly
Transaxle Assembly, Continued:
6. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simultaneously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation (Figure 16-13, Page 16-8).
7. Install both dowel pins (27) (Figure 16-3, Page 16-3) or (25) (Figure 16-4, Page 16-4) in the transaxle
housing (24 or 20).
8. Install left half of transaxle housing:
• For Type K transaxles:
8.1. Place a new gasket (13) (Figure 16-3, Page 16-3) in position on the mating face of the housing.
Use the dowel pins to position the gasket. Make sure all holes are aligned.
8.2. Install left half of transaxle housing (24) (Figure 16-3, Page 16-3).
8.3. Install the ten bolts (26) and tighten to 69 in.lb (7.8 N-m) (Figure 16-3, Page 16-3).
8.4. If the axle tube (16 and 40) was removed, install the shims (39), (if the shims were removed) and
a new gasket. Install the axle tube with five lock washers and bolts (9 and 8) (Figure 16-3, Page
16-3). Tighten the bolts to 22 ft. lb (30 N-m).
NOTE
• TYPE K TRANSAXLES: IF THE DIFFERENTIAL CASE (33 AND 36), THE TRANSAXLE HOUSING
(11 AND 24) OR AXLE TUBE (16 AND 40) (FIGURE 16-3, PAGE 16-3) WAS REPLACED, SEE
SHIMMING THE TRANSAXLE ON PAGE 16-13.
• For Type G transaxles:
8.1. Place 1/8 in. bead of three bond liquid gasket on mating face of housing. See following NOTE.
NOTE
• TYPE G TRANSAXLES DO NOT USE A GASKET ON THE MATING FACE OF THE HOUSING. USE
AN 1/8 IN. BEAD OF THREE BOND LIQUID GASKET INSTEAD.
8.2. Install left half of transaxle housing (20) (Figure 16-4, Page 16-4).
8.3. Install eleven bolts in the case housing and tighten to 19 ft.lb (25.7 N-m). Type G transaxles have
no shims or gasket.
8.4. Install axle tube with lock washers and bolts (9 and 8) (Figure 16-4, Page 16-4). Tighten the bolts
to 36 ft.lb (49 N-m).
• For all transaxles:
9. Install the brake assemblies as instructed in Section 6–Wheel Brake Assemblies.
10. Apply a small amount of grease to the lip of the oil seal (17) (Figure 16-3, Page 16-3) or (15) (Figure
16-4, Page 16-4).
11. Clean the splines on the axle shaft (1 and 2). Rotate the axle to align the shaft splines with the splined
bore of the differential side gear. Push the shaft in until the bearing seats against the shoulder in the
axle tube (Figures 16-3 and 16-4, Pages 16-3 and 16-4).
12. Install the retaining ring (6) (Figures 16-3 and 16-4, Pages 16-3 and 16-4) in the axle tube. See
WARNING on page 16-6.
13. Make sure the drain plug is installed in the transaxle and tightened to 23 ft.lb (31 N-m). Fill the transaxle, through the level indicator hole, with 22 ounces of SAE 30 API Class SE, SF, or SG oil (a higher
grade may also be used). Install and tighten the level indicator plug to 23 ft.lb (31 N-m).
Page 16-12 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
TRANSAXLE
Transaxle Installation
SHIMMING THE TRANSAXLE
Type K Transaxles Only
If the differential case (36 and 33), transaxle housing (11 and 24), or axle tube (16 and 40) has been replaced, the
transaxle may need new shims. To determine whether new shims are necessary, the transaxle must be completely
assembled except for the short axle tube (16) and both axle shafts (1 and 2) (Figure 16-3, Page 16-3).
1. Stand the transaxle on end, on the axle tube.
2. Using a depth gauge, measure the distance from the gasket seal surface of the axle tube (gasket must
be removed) to the outer race of the bearing (14) on the differential case assembly (32) (Figure 16-3,
Page 16-3) See also Figure 16-21, Page 16-13.
3. Use the following charts to determine whether shimming is required and, if so, how many shims (Club
Car Part No. 1013781) should be used.
Up to .134 inches (3.4 mm)
0
.134 -.142 inches (3.4 - 3.6 mm)
1
.142 -.150 inches (3.6 - 3.8 mm)
2
.150 -.155 inches (3.8 - 3.9 mm)
3
70
60
80
90
1
50
30
40
SHIMS
REQUIRED
10
20
Distance from gasket seal surface
to outer race or bearing INCHES (MM)
Figure 16-21 Depth Gauge
TRANSAXLE INSTALLATION
See DANGER and WARNING on page 16-1.
1. If using a chain hoist, raise the vehicle and place transaxle in position on the jackstands. If using a floor
jack, lower the jackstands to their lowest settings and place the transaxle in position on the jackstands.
2. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.
3. Install the two U-bolts, jounce bumper mount and spacers, lockwashers, and nuts. Tighten the nuts to
25 ft.lb (34 N-m). Tighten the U-bolt nuts so an equal amount of thread is visible on each leg of the bolt.
4. Install the motor. See Section 15–Motor.
1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement Page 16-13
16
16
TRANSAXLE
Transaxle Installation
Transaxle Installation, Continued:
5. If using a chain hoist, lower the vehicle while guiding the leaf springs into the rear spring shackles. If
using a floor jack, raise the differential while guiding the leaf springs into the rear spring shackles. Then
raise the jackstands to support the transaxle.
6. Reconnect the four motor wires. Tighten the retaining nuts to 65 in.lb (7.3 N-m). Use two wrenches to
prevent the motor studs from turning. See following NOTE.
NOTE
• IF THE MOTOR WIRES WERE NOT TAGGED WHEN DISCONNECTED, SEE SECTION 11,
FIGURES 11-2 THROUGH 11-6, PAGES 11-3 THROUGH 11-7, WIRING DIAGRAMS FOR
PROPER CONNECTION.
7. Insert bolts through the spring shackles and bushings in the leaf spring eyes. Secure bolts with lock nuts.
Tighten to 15 ft.lb (20.3 N-m).
8. Connect the brake cables.
9. Install the shock absorbers. Tighten shock absorber retaining nuts until the rubber bushings expand to
the same size as the cup washers.
10. Install the rear wheels and finger tighten lug nuts.
11. Lift the vehicle and remove the jackstands. Lower vehicle and tighten lug nuts (using a criss-cross pattern) to 55 ft.lb (74.6 N-m).
12. Test drive the vehicle to check for proper operation.
Page 16-14 1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement