Club Car 1996 DS Golf Car Gasoline Service Manual Download

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Page 9-13

• If the original differential cage gear assembly included all thrust washers (1, 2, 3, and 4) (Figure 9-24),

and lock plates (Figure 9-21, Page 9-1), discard the two new thrust washers (1 and 2) (Figure 9-24)
from the kit and the case side gear thrust washer (3) from original assembly, then install the remaining
original thrust washers and gears into the new left differential gear case (Figure 9-24).

• If three thrust washers (1, 2, and 3) (Figure 9-24) and the lock plates (Figure 9-21) were not included

in the original configuration, use the original thrust washer (4) (Figure 9-24), both new thrust washers
(1 and 2) (Figure 9-24), and the new left differential gear case from the kit.

• If the thrust washer (3) (Figure 9-24) and lock plates (Figure 9-21) were not included in the original

configuration, use the two new thrust washers (1 and 2) and the new left differential gear case included
in the kit.

3. Install the pin (31) (Figure 9-1, Page 9-1).

4. Apply a small amount of oil to all thrust washers and to both ends of the pin installed in Step 3.

5. While aligning the dowel pin, assemble the two halves of the differential cage gear (32 and 37) and

reinstall the ring gear (30) (Figure 9-1, Page 9-1).

6. Reinstall eight hex bolts and the bolt lock plates (if lock plates were included in original assembly) (28

and 29) (Figure 9-1, Page 9-1). Tighten the bolts to 16-20 ft.lbs. (21/27 N-m).

7. Bend up 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.

8. Press a new bearing (20) (Figure 9-1, Page 9-1) onto the intermediate gear assembly.

9. If the large gear (23) was removed from the intermediate gear, insert the key (22) into the keyway in the

shaft and then press the large gear and the bearing (18) (Figure 9-1, Page 9-1) onto the shaft. Be sure
that the key is properly positioned in the keyway before attempting to press on the large gear and bear-
ing.

10. Press a new bearing (18) (Figure 9-1, Page 9-1) onto the input pinion gear.

11. Apply grease to the lip of the new oil seal (10) (Figure 9-1, Page 9-1) and install the seal using a tran-

saxle pinion seal tool (Club Car Part No. 1014161). The lip of the oil seal should face to the inside of the
transaxle housing. Make sure that the seal is firmly seated.

12. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simulta-

neously. Be sure that all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation (Figure 9-18, Page 9-9).

13. Install both dowel pins (27) in the transaxle housing (11) and place a new gasket (13) (Figure 9-1,

Page 9-1) in position on the mating face of the housing. Use the dowel pins to position the gasket, mak-
ing sure that all holes are aligned.

14. Apply a gasket adhesive, if necessary, to one side of the gasket and install the other half of the hous-

ing.

15. Install the ten bolts (26) (Figure 9-1, Page 9-1) and tighten to 60-78 in.lbs. (7/9 N-m).

16. If the axle tube (16 and 39) was removed, install the shims (38) (Figure 9-1, Page 9-1), if they were

removed also, and a new gasket with gasket sealing compound on one side. Install the axle tube with
five lock washers and bolts (9 and 8) (Figure 9-1). Tighten the bolts to 20-24 ft.lbs. (27/32 N-m).

Club Car 1996 DS Golf Car Gasoline, Service Manual

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