27660-G01 0 EECompany SHOP REBUILD AND SERVICE PARTS MANUAL FOUR CYCLE TRANSAXLE STARTING MODEL YEAR: 1992 REVISED: 06/15/00SHOP REBUILD AND SERVICE PARTS MANUAL 4-CYCLE TRANSAXLE .Z.GO Division of Texton reserves the right o make design changes without obligation to make these changes on unis previously sid and th information Contained in is manuals subject o change witout nee -Z-GO Division of Toxton nt able for ero inthis manual ror incidental or consequential damages that result rom tho use o he materia in this manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609 E-Z-GO DIVISION OF TEXTRON, INC., P.0.BOX 388, AUGUSTA, GEORGIA USA 30903-0388 Transaxle Shop Rebuild and Parts Manual Page iNOTES Page ii Transaxle Shop Rebuild and Parts ManualINTRODUCTION ead allo each secon before attempting ary procedure, Pay patel attention to al Noles, Cautons and Warnings HOW TO USE THIS MANUAL This manual is designed to suit the needs of mechanics at all levels of experience with the E-2-GO 4-cycle transaxle. The outline format will allow the mechanic to choose the level of instructional detail needed to com- pletely disassemble, diagnose, repair/overhaul and reas- semble the transaxle. The manual is divided into four major operational sec- tions, which are each divided into smaller operational sections. At the beginning of each major section is a list of tools that will be required to perform the operations desired in that section. Do not use non-specified tools (vise grips®, hammers, adjustable wrenches etc.). The use of these tools could cause permanent damage to the transaxle components ‘The objective of this manual is to provide instructions for the disassembly and reassembly of the transaxle after it has been removed intact from the vehicle. Although we strongly recommend that the entire transaxle be removed from the vehicle before attempting to disassem- ble or repair any part of it, there are several operations, covered that may be completed, on only one side of the transaxle at a time, without removing the entire transaxle: 1. Remove and inspectireplace one axle shaft andlor axle shaft bearing. 2, Remove and inspect one axle tube. 3. Inspeetiteplace one axle oil seal in the transaxle cas- ing. 4, Remove and inspectireplace the input shaft, shifter shaft, and governor shatt cil seals. We strongly recommend that no matter what your experi- ence level, you use this manual as a guide when disas: sembling, repalringioverhauling and reassembling the transaxle. Before working on the transaxle, read and understand the text and in particular each NOTE, CAU- TION and WARNING. ‘Some illustrations may show components that differ from your transaxle. This is the result of ongoing improve- ‘ments to the transaxle design. NOTES, CAUTIONS AND WARNINGS ‘Throughout this manual, the following NOTES, CAU- TIONS and WARNINGS are used. For the protection of all personnel and the vehicle, be aware of and observe the following: NOTE A NOTE indicates a condition that should be observed. A CAUTION indicates a condition that pa iy cesuit in damage tothe vehicle or ‘surrounding facilities. A WARNING indicates a WINUZNIINEV hazardous condition which could result in serious injury or death. IMPORTANT SAFETY WARNINGS In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. Its virtually impossible to anticipate all possible compo- nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there- fore should be considered potentially hazardous. Use ‘extreme care when working on any vehicle. When diag- nosing, removing or replacing any components that are not operating correctly, take the time to consider the safety of yourself and others around you if the compo- rnent should move unexpectedly. Some components are heavy, spring loaded, highly cor- Tosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders it not treated with utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur. ‘Always use the appropriate tools listed in the tool list and wear approved safety equipment. Before working on vehi- FI NUZNESTISEY'W cle, remove ail jewelry (watch, rings, necklaces, etc Be sure that no loose clothing or hair can contact moving parts. lezen) Transaxle Shop Rebuild and Parts Manual Page iiiINTRODUCTION Read all ofeach secon before attempting any procedure. Pay partici attention to al Noles, Cautons and Warings Wear eye protection when working on or TY around vehicle. In particular, use care 4 when working around batteries, or when A” using solvents or compressed air. Use care not to contact hot objects. Before attempting to operate or adjust the powertrain, the rear of the vehicle must be raised and supported on jack stands. Wear OSHA approved clothing and eye protection when working on anything that could expose the body or eyes to potential injury. In particular, use care when working with or around batteries, compressed air or solvents. ‘Always turn the key switch to ‘OFF’ and remove the key before disconnecting a live circu. When connecting battery cables, pay particular atten- tion to the polarity ofthe battery terminals, Never con- fuse the positive and negative cables. Battery posts, terminals and related accessories con- tain lead and lead compounds. Wash hands after han- diing. Set the parking brake before performing any work on the vehicle. Keep all smoking materials, open flame or sparks away from gasoline or batteries. If repairs are to be made that will require welding or cutting, the battery and fuel tank must be removed and the fuel system drained. Never operate the starter withthe spark plugs removed unless the ignition system has been dis- abled and the engine/exhaust is cold. Fuel expelled from the cylinders could be ignited by the ignition system or the hot exhaust system. Never work on an engine that is hot. ‘Never work around or operate a vehicle in an environ- ‘ment that does not ventilate exhaust gases from the area. Exhaust gas (carbon monoxide) is deadly. Carbon monoxide is an odorless gas that is formed as a natural part of the incomplete combustion of hydro- carbon fuels. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. The following are symptoms of carbon monoxide inhalation: + Dizziness + Vomiting + Intense headache + Muscular twitching + Weakness and sleepiness + Throbbing in temples {f experiencing any of these symptoms, get fresh air immediately. Never test the ignition system without either connect- ing the spark plug lead to a tester or spare grounded spark plug. {tthe spark function is to be observed at the spark plug, be sure to install a spare spark plug into the open cylinder before operating the starter. Never test the function ofa fuel pump in the vicinity of a hot engine or other source of flame or combustion. Never confuse the hoses to and from the fuel pump. Verify that the carburetor and pulse lines are correctly installed before starting the engine (see FUEL SYS- TEM Section in your Repair and Service Manual). Aerosol containers of battery terminal protectant must be used with extreme care. Insulate the metal container to prevent the metal can from contacting battery terminals which could result in an explosion. Page iv Transaxle Shop Rebuild and Parts ManualTABLE OF CONTENTS TITLE SECTION Introduction....... Transaxle Disassembly Inspection and Replacement of Pats ...::ss:nusitnnstnainnnnstnnstnistnensinsnesenee Transaxle Reassembly...... Illustrated Parts breakdown...... (Er) Transaxle Shop Rebuild and Parts Manual Page vTABLE OF CONTENTS Notes: Page vi Transaxle Shop Rebuild and Parts ManualTRANSAXLE DISASSEMBLY TRANSAXLE DISASSEMBLY Tool List Extension, 4", 3/8" drive ..... ‘Small diameter pick-up magnet Rubber mallet, medium.. ‘Snap ring pliers, medium ‘Snap ring pliers, small Standard pliers. Seal puller... Ratchet, 3/8" drive. Ratchet, 1/2" drive... Flat blade screwdriver, small Phillips screwdriver, #2 ...... ‘Socket, 12mm, 3/8" drive Socket, 14mm, 3/8" drive... ‘Socket, 17mm, 3/8" drive Socket, 1/2", 3/8" drive..... Socket, 1 1/8", 1/2" drive, Combination wrench, 12mm... ‘Combination wrench, 1/2", Lug wrench, 3/4” [NOTE] #1, assured that the wheels have bean removed, the oil drained from the transaxle, land that the transaxle has been removed from the vehicle. t these things have not been done, do so before continuing with this section. Refer to the Repair and Service Manual of the spe- cific vehicle for information and safety considerations when removing the transaxle. Qty. Required A Press fit shaft bearings should be cleaned and inspected: and replaced only if they appear to be damaged or excessively worn. Replace bearings that are pitted, nicked, burred, discal ‘red, or that rotate roughly or noisily. Keep work area clean PRENIN and well organized wile performing the opera- tions described in this manual. This will help prevent accidents and reduce the possibilty of mistakes that ‘could damage or impair the performance of the tran- saxle. Because some mating parts with wear Rae LSIA siriaces were machined together when the transaxle was manufactured, or have established wear pat- tems during operation, the reassembly of parts in their orginal Positions and orientations, with their original mating parts, critical othe performance and le expectancy of the transaxle. ‘Mark and sor all pars as they are disassembled so that they will be reassembled and installed in thei original positions. Wheel Brake Removal Brake removal wil vary between models and NOTE) jrechanical of hydraulic brakes, Typical ‘mechanical brakes are shown, Please refer 10 tho Repair and Senice Manual for your specie brake removal procedure. 1. Attach a wheel and tire to the brake hub on the driver (clutch) side axle tube and stand the tran- saxle on end, with the wheel as a base (Ret Fig. At on page A1). Fig. A-1 Axle Stand 2. Remove the cotter pin (1), axle nut (item 2, 1 1/8" socket), washer (3), and cup washer (4) (if present) from the right side axle shaft (Ref Fig. A- 2.0n page A-2). 3. Pull the brake drum (5) from the axle (10), and remove the washer (7) (Ref Fig. A-20n page A-2). When the vehicle was manufactured, an ant NOTE) 20 compound was applied tothe axle shat splines to prevent the brake drum from bonding to the shaft. t the brake drum has since been removed and reinstalled without an anti-seize compound, removal ofthe drum may require the iso ofa slide hammer. ‘A.Using a 1/2" socket, remove the four bolts (8) and ruts (9), and detach the brake assembly (6) from the top (passenger) side axle tube (11) (Ref Fig A-2 on page A-2). lezen) Transaxle Shop Rebuild and Parts Manual Page A-tTRANSAXLE DISASSEMBLY Fig. A-2 Wheel Brake Removal Axle Shaft and Axle Tube Removal 1. Remove the top (passenger) side axle shaft (1) (Ref Fig. A-3 on page A-2). ‘A.Using snap ring pliers, remove the bearing retait ing ring (2) from the end of the axle tube (3). B.Carefully pull the axle shaft and bearing out of the tube. 2. Remove the top (passenger) side axle tube from transaxle casing (4) (Ref Fig. A-3 on page A-2). ‘A.Using a 17mm socket, remove five nuts (5) and washers (6) attaching the tube to the casing (some models may use bolts) and carefully lift the tube from the casing studs. 3. Using a seal puller, remove the axle shaft seal (7) from the casing (Ref Fig. A-3 on page A-2)(Ref Fig, A-4 on page A-2). (late production) (early production) 5 3 Seal puller Fig. A-3 Transaxle Breakdown Fig. A-4 Axle Shaft and Tube Removal FeV NE pa Tep Ny 20 not scratch, score, or damage the seal bore in any way. This could cause ‘he seal to fall. Removing Shifter Cable Mounting 1. Remove the shifter cable mounting bracket (8) (Ref Fig. A-3 on page A-2). ‘A.Using a 12mm socket, remove the two (2) bracket mounting/transaxle casing bolts (9) and pull the bracket from the casing B.Attach the mounting bolts to the bracket in their original positions so that they can be easily installed in their original positions when reassem- bling the transaxle, Using a 12mm socket, remove the two accelera- tor bracket mounting/transaxle casing bolts (10) (Ref Fig. A-3 on page A-2). Page A2 Transaxle Shop Rebuild and Parts Manual lezen)TRANSAXLE DISASSEMBLY These are the longest bots inthe casing. They LNGTE) 25 oach of dforont longtns and both aro longer than all the others. They are also installed opposite in direction to all the other casing bolts. Mark these bolts so that they will be reinstalled in their proper positions. 3. Using a 12mm socket, remove the six remaining casing bolts (11) (Ref Fig. A-3 on page A-2). 4, Remove the shifter detent (Ref Fig. A-3 on page AQ). A.Using a 14mm socket, remove the shifter detent bolt (12), B.Using a small magnet, remove the spring (13) and ball (14) from the shitter detent bolt hole. Separating Differential Case 1. Remove the top (passenger side) half of the tran- saxle casing (4) (Ref Fig. A-3 on page A-2). A.Using a wooden or rubber mallet, gently tap ‘around the casing joint to loosen the seal. B. Grip the axle tube studs on the top haif of the cas- ing and pull up while gently tapping upward on the ‘governor shaft boss until the top half of the casing separates. Carefully remove the case half and gasket (Ref Fig. A-5 on page A-3) C.lf the input shaft bearing (15) (Ref Fig. AS on page A-2) stays on the shaft when the top half of the case is lifted, remove it from the shaft and mark it for location. 2. Remove two transaxle case alignment dowels (16) and gasket (17) (Ref Fig. A-3 on page A-2). Differential Case Disassembly 1. Remove the counter shaft (18), reverse idler gear (19), and three spacers (20) (Ref Fig. A-3 on page A2). 2. Remove the input shaft assembly (21) (Ref Fig. A- 3.0n page A-2). A.Lift the differential carrier assembly (22) until the final drive gear (23) touches the intermediate gear shaft bearing (24) and hold it in this position (Ref Fig. A-6 on page A-3). B. While holding the final drive gear against the bear- ing, gently tap straight up on the end of the input shaft until the input shaft assembly is free from its seating in the casing (Ref Fig. A-6 on page A-3) 3. Remove the differential carrier assembly, the intermediate gear shaft assembly (25), and the shifter fork (26) (Ref Fig. A-3 on page A-2). Axle tube studs were early production Grip the axle tube studs and pull up while gently tapping upward on the governor shaft boss. Use a rubber mallet Fig. A-5 Separating Differential Case Hold final drive gear against the intermediate gear shaft bearing, Intermediate gear \ Final drive gear shaft bearing Gently tap straight up on the input shaft with a wooden mallet. Fig. A-6 Differential Case Disassembly lezen) Transaxle Shop Rebuild and Parts Manual Page A:3TRANSAXLE DISASSEMBLY ‘A.Hold the shifter shaft fork, intermediate gear shaft assembly, and differential carrier assembly together and lft them as one unit from the casing. 4. Remove the selector shaft (27) (Ref Fig. A-3 on page A-2). ELSERAIETNY ©2102 score, or damage the ‘eal bore in any way. This could cause the seal to fall, A.Using a small, sharp screwdriver or other suitable tool, carefully remove the oil seal (28) from the selector shaft bore. B.Use a small pair of snap ring pliers to remove the snap ring (29) and spacer (30). C.Remove the selector shaft. 5. Remove the governor fork (1) from the top half of the casing (2) (Ref Fig. A-7 on page A-4). Part of casing is cutaway to show position of governor shaft when installed, Fig. A-7 Governor fork Removal Do nat scratch, score, or damage the pata) ‘seal bore in any way. This could cause the seal to fail. A.Using a small sharp screwdriver or other suitable tool, carefully remove the governor shaft seal (3). B.Using a #2 Phillips screwdriver, remove two screws (4) with washers attaching the governor fork to the governor fork shatt (5) C.Remove the shaft retainer (6) and governor fork. D.Pull the governor fork shaft from the casing, 5. If the input shaft bearing (7) is still in the casing bore, remove and mark it for location (Ref Fig. A- 7 on page A-4). 7. Using a 17mm socket, remove five nuts (1) with washers and detach the driver side casing half from the driver side axle tube (Ref Fig. A-8 on page A-4). (early production) 1 (late production) 1 Fig. A-8 Differential Case Removal 8. Using a seal puller, carefully remove the remain- ing oil seals (1, 2) from the casing (Ref Fig. A-9 Fig. A-9 Oil Seal Removal Page A-4 Transaxle Shop Rebuild and Parts ManualTRANSAXLE DISASSEMBLY 9. Remove the wheel from the driver side hub. 10. Remove the cotter pin (1), axle nut (2) using a1 1/ 8" socket, washer (3), and cup washer (if present) (4) from the driver side axle shaft (Ref Fig. A-10 on page A-5).. Fig. A-10 Axle Shaft Removal 11. Pull the brake drum (5) from the brake assembly (6), and remove the washer (7) (Ref Fig. A-10 on page A-5). 12. Using a 1/2" socket, remove the four (4) bolts (item 8) and nuts (9), and remove the brake assembly from the driver side axle tube (Ref Fig. ‘A-10 on page A-5). 13. Remove the driver side axle shaft (10) (Ref Fig. ‘A-10 on page A-5). ‘A.Using snap ring pliers, remove the beating retain- ing ring (11) from the end of the axle tube (12) (Ref Fig. A-10 on page A-5). B. Carefully pull the axle shaft out of the tube. Transaxle Shop Rebuild and Parts Manual Page A:5| TRANSAXLE DISASSEMBLY Notes: Page AS Transaxle Shop Rebuild and Parts ManualINSPECTION AND REPLACEMENT OF PARTS INSPECTION AND REPLACEMENT OF PARTS Tool List Qty. Required Vernier calipers Depth gauge Feeler gauge set Telescoping gauge set Micrometer, 1” Micrometer, 2 Micrometer, 3 Bearing puller... Medium non-ferrous punch ‘Small non-ferrous PUNCH... Medium flat blade screwdriver Philips screwdriver, #2 Surface plate We strongly recommend that all parts found to NOTE) 5. Gamaged or out of spoctied limits. be replaced. We recommend that parts found to be acceptable but near limits be replaced ifthe vehicle will see high usage. Telescoping gauges and hole gauges are ‘transfer type" mea- suring instruments. they are not calibrated and are used to record a distance which is then transferred to a micrometer for measurement. Position the gauge in the hole or bore and “set” the telescoping arms or ball to its true diameter. Make sure that the handle of the gauge is inline with the centerline of the hole ‘or bore. Remove the gauge and measure its setting with a ‘micrometer (Ret Fig. 8-1 on page B. 1). EERIE 312" ms be thorougiy cleaned, and free of all dir, oil, grease, or resi- due of any kind before beginning this section. It is especially important that your work area be clean and well organized while performing the operations described inthis section. Oil Seal and Bearing Inspection 1. Inspect all oil seals for damage of any kind. TNOTE] “i recommended that any oi! seals that are [NOTE] removed, and al seals fa transaxle is more than one year old when disassembled, be replaced with new ones. 2. Inspect all bearings for damage and excessive wear. Replace bearings that are pitted, nicked, burted, discolored, or that rotate roughly or nois- ily. [NOTE] Femove press ft bearing only it they are dam: aged, excessively worn, or if it is necessary in ‘order to remove other pars. Its recommended that removed press ft bearings be replaced with new ones. Fig. B-1 Telescoping and Hole Gauge Axle Shaft and Tube Inspection 1. Check shafts for straightness. 2. Check journal diameter (A, B, C) (Ref Fig. B-2 on page B-2). A.Inspect splines for obvious fretting, twisting, or damage of any kind (Ref Fig. B-2 on page B-2). B. Inspect threads and seal areas for damage. C. inspect axle tubes for damage of any kind. Check for straightness, Differential Case Inspection 1. Inspect casing halves (1, 2) for damage of any kind (Ref Fig. B-3 on page B-2). Hi flatness of a gasket surface is found BaD 5 0 out of tolerance by more than 004, the part must be replaced. A Place each case half on a surface plate, gasket surface down, and check for flatness using a .004 feeler gauge. If the gauge can be inserted any- where under the case half, the transaxle casing must be replaced. B. Inspect bearing and shaft bores for damage of any kind. lezen) Transaxle Shop Rebuild and Parts Manual Page B-1INSPECTION AND REPLACEMENT OF PARTS [specs] A 3 é = 0006], +0076 ggg + 05 eae ‘ooo08 |" 003 ae 0025} S018 | p92 80 | pg 2080 rom | 252018 [o0%09 | a5 7080 i o \ [ ll 3 BS t 8 Type Measure each position in2 places 90° apart ©? ve Fig. B-2 Axle Shaft and Tube Inspection Governor Shaft and Fork Inspection 1 Inspect the governor shaft (1), governor fork (2), and shaft retainer (3) for damage of any kind. Check governor fork tangs for wear (Ref Fig. 8-4 on page B-2). Shifter Shaft and Fork Inspection 1. Inspect the shifter shaftifork (1) for wear or dam- age of any kind (Ref Fig. B-5 on page B-3). Counter shaft and Reverse Idler Gear Inspection 1. Inspect the counter shaft (1), reverse idler gear (2), and spacers (3) (Ref Fig. B-6 on page B-3). A.Inspect the shaft, gear, and spacers for scoring, chipping, broken teeth, ete, B. Measure the outside diameter of the shaft at the Position shown, in two places 90° apart C.Measure the inside diameter of the gear bushing at two places 90° apart as shown. (004 Feeler gauge 1s ae 2 «el Ge SPECS A sto. | 17+ .oo1s mm | 43+ 037 Both tangs Fig. B-4 Governor Shaft and Fork Inspection Page B-2 Transaxle Shop Rebuild and Parts Manual lezen)INSPECTION AND REPLACEMENT OF PARTS SPECS A stb. 24" + 012 mm. 60 + 03 Fig. B-5 Shifter Shaft and Fork Inspection oa” specs] A sto] 660" (om) | 7) user © (mm) | -.0004" (011) 1 RB at ‘Typical: Measure in 2 places 90° apart SPECS| 8 STD. 569" (mm) a) Limit | +.0010"(.026) (mm) | -.0018"(.045) Fig. B-6 Counter Shaft and Reverse Idler Gear Inspection Transaxle Shop Rebuild and Parts Manual Page B-3INSPECTION AND REPLACEMENT OF PARTS Input Shaft Inspection B. Inspect input shaft (3) for chipped splines or gears, 1. Inspect the input shaft assembly (1) (Ref Fig. B-7 excessive wear, or damage of any kind, on page B-4). 2. If necessary, disassemble the input shaft assem- NOTE]! :2commend thatthe complete assembly be bly. replaced if any partis found to be damaged. NOTE] 2% the governor sleeve and the governor ‘A. Inspect the governor sleeve (2) for excessive wear iste con Be Cees ‘or damage of any kind. MS. nie VAN aay, in 2 places 90° apart { » 2 y, specs] 8 c ry +003. [ggq-*0008 | 9g, +0016 | og, +007 STD. |-984" "014 [°° 00016] 94 “003 | 988 “002 +085 | 5 +009 +040 “1.085 mm | 25-035 | 7-004 | * 073 | 7-035 Fig. B-7 Input Sheft Inspection Page B-4 Transaxle Shop Rebuild and Parts Manual =r)INSPECTION AND REPLACEMENT OF PARTS Intermediate Gear Inspection 1. Inspect the intermediate gear and shaft assembly (1) (Ref Fig. B-8 on page B-5). A. Check for a close fit between the gears (2, 3) and the shaft (4). Gears should spin evenly on the shaft without “play” or wobbling. B. Inspect gear teeth and shaft splines for damage of any kind, C.Check pin clutch motion. Pin clutch (5) should slide freely on the shatt. D.inspect pin clutch teeth and pin clutch engage ment holes in the gears for damage of any kind. 2. It necessary, disassemble the intermediate gear and shaft assembly (Ref Fig. 8-8 on page B-5). ‘A. Using a three jaw bearing puller, remove the bear- ing (6), B. Remove the spacer (7), collar (8), output gear (9) collar (10), reverse gear (2), spacer (11), and pin clutch (5) from the shat. C.Using a three jaw bearing puller, remove the bear- ing (12). D.Remove the spacer (13), drive gear (ITEM 3), and spacer (14) from the shatt 5 ‘Typical: Measure each position in2 places 90° apart SPEC: x 5 *o013| +0078] og4r 0 STD. |.964' 984" Pos! mm | 25 7020 0 033 | 25 .o13 c D 7.0008) ggg =-0078 964" * 0005) gage +001 +073 0 25 073] 25 8. Fig. B-8 Intermediate Gear and Shaft Inspection Transaxle Shop Rebuild and Parts Manual Page B-5INSPECTION AND REPLACEMENT OF PARTS Differential Carrier Inspection 1. Inspect the differential carrier assembly (Ref Fig. B-9 on page B-6). ‘A.Make sure that the ring gear (1) is properly posi- tioned and fastened securely to the carrier hous- ing (2), B. Inspect the ring gear for damage of any kind, C. Inspect the pinion gears (3, 4) and side gears (5, 6) inside the housing for damage of any kind. D.Check the pinion gear shaft (7) and pinion gears for proper close fit. Gears should spin evenly on the shaft without “play” or wobbling. 2. If necessary, disassemble the differential carrier assembly (Ref Fig. B-9 on page B-6). Because of wear patterns created during oper: NOTE) sion itis recommended thatthe prion shat pinion gears, and side gears not be replaced individually. Replace all ofthese as a set. A. Using a three jaw bearing puller, remove the bear- ing (8), B.Using a 17mm socket, remove four (4) bolts (9) attaching the ring gear (1) to the carrier housing (2). Carefully remove the ring gear and the first side gear (6). C.Remove the pinion gear shatt (7). 1) Using a suitable punch, GENTLY tap out the pinion shaft locking pin (10). 2) Using a suitable punch, GENTLY tap out the pinion shaft and remove the two pinion gears (3, 4) and the second side gear (5). D.If the carrier housing bearing (11) is to be removed, use a bearing puller to remove it Fig. B-9 Differential Carrier Inspection Page B-6 Transaxle Shop Rebuild and Parts ManualTRANSAXLE REASSEMBLY TRANSAXLE REASSEMBLY Tool List Qty. Required Extension, 4", 3/8" drive, 1 ‘Small ball peen hammer... Seal installer Rubber mallet, medium... ‘Snap ring pliers, medium ‘Snap ring pliers, small Standard pliers Mechanical press... Non ferrous punch, medium Non-ferrous punch, small... Ratchet, 3/8" drive. Ratchet, 1/2" drive... Flat Blade screwdriver, medium Phillips screwdriver, #2 Socket, 12mm, 3/8" drive Socket, 14mm, 3/8" drive Socket, 17mm, 3/8" drive Socket, 1/2", 3/8" drive. Socket. 11/8", 1/2" drive... Combination wrench, 12mm Combination wrench, 1/2"... Lug wrench, 3/4" Torque wrench, 3/8" drive... EERE *'2 ansastereassomby, a parts ‘must be thoroughly cleaned; free of dit, oll, grease, of residue of any kind; free of nicks, burrs, of damage of any kind to wear surfaces; and inspected for exces- sive wear. Parts that are damaged or are not within dimensional specifications should be replaced. Because some mating parts with wear surfaces were machined together when the transaxle was manufactured, or have estab- lished wear patterns during operation, the reassembly of tran- saxle parts in ther original positions and orientations with theit original mating parts is critical to the performance and life expectancy ofthe transaxle. When tightening a number of screws or bolts ina given pattern, tighten them in two stages. Tighten them to 1/2 of specified torque in one pass through the pattern, and then to specified torque on the second pass. Fasteners that are plated, or are lubricated UNGTE) ion installed, are. considered “wet" and require approximately 80% ofthe specified torque for “dry” fas teners, All transaxle fasteners are considered “wet” (Ret Fig. C- 26 on page C-11) Because assombles of moving pats estabish NeTe wear patterns together, it is recommended that ail parts ofan assembly be replaced if one partis found to be damaged. Noise levels ding operation may be increased if onl indvoual pars are replaced. Apply Loctite carefully. Make sure that be one is accidentally applied to surfaces ‘other than those for which its intended. Reassemble the Input Shaft Assembly 1. Position the governor plate (2) on the input shaft (3) and install the lock pin (4) and two screws (5). Use 262 Loctite on lock pin and screw threads, and tighten to specified torque (Ref Fig. C-1 on page C-1). 2. Install the governor sleeve (6) on the input shaft, with the lock pin in the notch as shown. Fig. C-1 Input Shaft Assembly Reassemble the Intermediate Shaft Assembly 1. Install the spacer (2), drive gear (3), and spacer (4) on the intermediate gear shaft (5) as shown (Ret Fig. C-2 on page C-2). 2. Using a mechanical press, install a new bearing (6) onthe shatt. 3. Install the pin clutch (7), spacer (2), reverse gear (8), collar (9), output gear (10), collar (11), and ‘spacer (12) on the shaft as shown. 4, Using a mechanical press, install a new bearing (13) on the shaft. lezen) Transaxle Shop Rebuild and Parts Manual Page C-1TRANSAXLE REASSEMBLY Fig. C-2 Intermediate Shaft Assembly Reassemble the Differential Carrier Assembly. Insert pinion shaft into the carrier housing bore. ‘Do not allow the shaft to protrude beyond the interior ‘opening of the bore. Fig. C-3 Differential Carrier Assembly 1. If the carrier housing bearing (2) was removed, use a mechanical press to install a new bearing (Ref Fig. C-3 on page C-2). 2. Position the side gear (3) in the carrier housing (4) as shown. 3. Start the pinion shaft (5) into the pinion shaft bore in the carrier housing with the locking pin hole oriented as shown. Do not allow it to pro- trude beyond the interior opening of the bore (Ref Fig. C-4 on page C-2). . Position the lower pinion gear (6) over the pinion Fig. C-4 Locking Pin Orientation shaft bore and continue pushing the pinion shaft through the gear as shown (Ref Fig. C-5 on page C2). ‘Mesh the lower pinion gear withthe side gear in the hhousing and position it over pinion shaft. Push the shaft through the pinion gear. Fig. C-5 Lower Pinion Gear Position Page C-2 Transaxle Shop Rebuild and Parts Manual lezen)TRANSAXLE REASSEMBLY 5. Position the upper pinion gear (7) over the lower one and push the pinion shaft through it and into the shaft bore in the carrier housing (Ref Fig. C-6 on page C-3). Mesh the upper pinion gear with the side gear and positon it over the lower one. Push the shaft through the upper pinion gear and into the cartier bor. Fig. C-6 Upper 6. Tap the pinion shaft into position and then, with a suitable punch, gently tap a new pinion shatt locking pin (8) into place as shown (Ref Fig. C-7 on page C-3). n Gear Posi It necessary, tap the shatt into position. Then, with a suitable punch, gently tap a new pinion shaft locking pin into place as shown. C-7 Pinion Shaft Locking Pin 7. Position the side gear (9) in the carrier, in mesh with the pinion gears, as shown (Ref Fig. C-3 on page C-2). 8 Using a mechanical press, install a new bearing (12) on the ring gear. 9. Position the ring gear (10) on the side gear (9) and carrier housing as shown and install four bolts (11) using a 17mm socket that attach the gear to the housing. Tighten the bolts to speci- fied torque. Oil Seal Installation Htusing press to install seals, adequate- at ly support the aluminum casing as close to the seal bore as possible. Fallure to do so could result, ina fractured casing. 1. Install any oil seals (1, 2, 3) that were removed. Lubricate seals with assembly lube (molybde- num disulfide) before installing them (Ref Fig. C- 8 on page 2 Fig. C-8 Oil Seal Installation tts recommended that any ol seals that wore NOTE removed, and all seals if a transaxle is more than one year ol when disassembled, be replaced with new seals. Transaxle Shop Rebuild and Parts Manual Page C-3TRANSAXLE REASSEMBLY Driver Side Axle Tube Installation 1 Install the left (clutch) side axle tube (1) on the left side transaxle casing half (2) (Ref Fig. C-9 on page C-4). (Early production) 3~ (Late production) Inner retaining fing Install the Driver Side Brake Assembly retaining ring (8) in the axle tube. [NOTE] Fig. C-9 Axle Tube/Casing installation The left (clutch) side axle tube is longer than the right side tube. ‘A Position the axle tube mounting plate on the cas- ing studs and install five nuts (3), using a 17mm. socket with new lock washers (4). Tighten the nuts. to specified torque. Install Driver (Clutch) Side Axle Shaft. I the bearing was removed from the axle shat, use a mechanical press to install a new bear- NOTE ing. The left (clutch) side axle shat is longer than the right side shat 1. Carefully insert axle shaft through the tube and casing oll seal until the shaft bearing (6) seats against the inner retaining ring (7) (Ref Fig. C-9 Fig. C-11 Brake Assembly Installation Position the brake assembly on the axle tube mounting plate and install four new bolts (3) using a 1/2" socket, and four new lock nuts (4) using a 1/2" socket that attach the backing plate to the axle tube. Tighten the bolts to specified torque. 2. Install the washer (5) as shown. on page C-4)(Ref Fig. C-10 on page C-4). 3. Install the brake drum (2) onto the axle and brake assembly. Page C-4 Transaxle Shop Rebuild and Parts Manual =r)TRANSAXLE REASSEMBLY A Lubricate (with Neverseize) the axle splines. B.(For NStiolder style brakes) Insert a straight blade screwariver between the adjusting lever and the adjusting mechanism, and rotate the star wheel counter-clockwise until the shoes have retracted enough to allow the brake drum to be installed (For Bendixinewer style brakes) Carefully lit the adjuster arm just enough to permit the star wheel to be rotated. Use great care not to force the adjuster arm which will cause permanent damage to the adjuster. The only recourse after damaging the adjuster arm is the replacement of both wheel brake assemblies. If no brake parts are to be replaced, turn adjuster screw ‘in’ 10 - 15 ‘clicks. C.Slide the brake drum into position. Install cup washer (6) (if used) and washer (7). Install the axle nut (8) using a 1 1/8" socket and cotter pin (9). A Install and tighten the axle nut to at least 70 ft. Ibs. If the slot in the axle nut is not aligned with the hole in the axle, continue tightening until they are aligned. B. Install a new cotter pin through the nut slot and axle hole, and bend the ends back to secure it Attach a Wheel and Tire 1. Attach a wheel and tire to the brake drum and stand on end with the wheel as a base (Ref Fig. -12 on page C-5). Fig. C-12 Position Axle on Base Install the Selector Shaft 1. Lubricate the shaft (1) with assembly lube (Molybdenum disulfide) and insert it into the cas- ing bore as shown (Ref Fig. C-13 on page C-5). Fig. C-13 Selector Shatt Installation While holding the shaft in position, install the washer (2) and then retaining ring (3) with a pair of snap ring pliers. Make sure the retaining ring is seated in the groove. Install a new seal (4). lezen) Transaxle Shop Rebuild and Parts Manual Page C-5TRANSAXLE REASSEMBLY Shifter Fork and Intermediate Gear Assembly Installation 1. Lubricate the shifter shaft and fork with assem- bly lube and position the fork on the pin clutch in ‘the intermediate gear assembly, with the two detent grooves up as shown (Ref Fig. C-14 on page C-6). restonsitr stone | onthe pn cutch Fig. C-14 Shifter Fork and Pin Clutch Assembly 2. Hold the shifter shaft and the intermediate gear assembly together as shown and place them in the casing. ‘A Orient the selector shaft fork upwards and engage the shifter fork actuator tang in the selector fork while lowering the shifter shaft and intermediate gear assembly into the casing (Ref Fig. C-15 on page C6). B. Guide the shifter shaft into its bore, while allowing the intermediate gear shaft bearing (7) to rest on the lip of (not seated in) its bore (Ref Fig. C-16 on page C-6). 3. Place the input shaft assembl (Ref Fig. C-17 on page C-7). A. Lubricate the input shaft splines and carefully insert the shaft through its oil seal in the casing. B.Mesh the input shaft gears with the intermediate shaft gears and hold them in position together. Do ‘ot allow them to seat in the casing. 4. Place the differential carrier assembly in the casing (Ref Fig. C-18 on page C-7). the casing Shifter fork actuator tang Selector Engage the shifter fork actuator tang inthe selector fork while lowering the shitter shaft and intermediate gear assembly into the casing Fig. C-15 Engaging Shifter Fork Actuator shiter shaft Intermediate goer shat ering = r ui nd shite shtt Imo bore ‘Allow intermediate gear shaft bearing to rest on the lip of (not seated in) its bore Fig. C-16 Locating Shifter Shaft Into Bore ‘A. While holding the input shaft gears and intermedi ate shaft gears in mesh and preventing them from seating, mesh the final drive gear on the differen- tial carrier with the output gear on the intermediate gear shaft. Page C-6 Transaxle Shop Rebuild and Parts Manual lezen)TRANSAXLE REASSEMBLY ‘Mesh input shaft {gear with intermediate {gear and hold them in position together Input shaft | assembly | a \ Lubricate and \\ | carfuly insert \ | input shaft \} through oil seal \) Do not allow assemblies to seat Fig. C-17 Input Shaft Assembly Intermediate Final Drive (Output Gear B. Hold the intermediate gear assembly and ditferen- tial carrier assembly together and allow them to seat together (they will not seat completely). 5. Seat all of the assemblies in the casing (Ref Fig. C-18 on page C-7). AHold the intermediate gear shaft assembly straight, and make sure that all gears in all assemn- blies are meshed with their mates. B.Hold the intermediate gear shaft assembly straight, and use a rubber mallet to lightly tap the input shaft assembly and shifter fork shaft until all assemblies fall into place. C.lt is possible that the differential carrier assembly will not have completely seated. If the final drive gear on the differential carrier assembly appears 10 be too high to mesh properly with the intermedi- ate output gear, slowly rotate the transaxle casing until the differential carrier assembly aligns with the axle shaft splines and drops into place. Install the Spacer, Reverse Idler Gear, Spacer, Counter Shaft, and Spacer 1. Position the spacer, on the shaft boss with the surface facing up (Ref Fig. C-19 on 2. Position the reverse idler gear on the shaft boss and spacer with the oil grooves facing up. 3. Position the spacer on the reverse idler gear with the machined side toward the gear. 4, Lubricate the counter shaft with assembly lube and insert it through the gear and two spacers and into the shaft bore as shown. 5. Place the spacer on the counter shaft with the machined side up. Input Shaft Bearing 1. Install the input shaft bearing in the top half (1) of the casing (Ref Fig. C-20 on page C-8). Slowly rotate transaxle casing to be sure the assemblies have seated completely Fig. C-18 Differential Carrier Installation Use a new bearing i there are any doubts NOTE about the condition of the original. Installing the Governor Fork Assembly ‘When lubricating the governor fork pt) ‘shaft, do not get lubricant in the thread- ed screw holes. 1. Lubricate the governor fork shaft (2) with assem- bly lube and insert it through the casing bore as. lezen) Transaxle Shop Rebuild and Parts Manual Page C-7TRANSAXLE REASSEMBLY Clutch Side Casing Half Fig. C-19 Input Shaft Bearing and Governor Fork ‘Assembly shown. Make sure the shaft rotates freely (Ref Fig. C-20 on page C-8). 2. Position the governor fork (3) and shaft retainer (4) on the fork shaft and install, but do not tighten, two screws (5) as shown, Use 262 Loctite (Ref Fig. C-20 on page C-8). 3. Press the shaft against the stop in the housing, ‘and then adjust the governor fork so that the diameter of its arc is concentric with the diameter of the input shaft bearing 4. Hold in this position and tighten the screws. Make sure the shaft rotates freely. 5. Install a new oil seal (6). Transaxle Case Dowels 1. Install two transaxle case alignment dowels (1) (Ref Fig. C-21 on page C-2). Position shaft retainer with tabs up, rounded tab toward the stop in the transaxle. Part of casing is cutaway to show position of governor ehatt when installed Fig. C-20 Input Shaft Bearing and Governor Fork ‘Assembly Transaxle Casing Gasket 1. Install a new transaxle casing gasket (2) on the left (clutch) side transaxle casing half, using the alignment dowels for positioning (Ref Fig. C-21 on page C-8). Install the Top (Passenger) Half of the Tran- saxle Casing 1. Make sure the casing half, and especially the gasket surface, is clean (Ref Fig. C-21 on page C- 9). the bearing from falling out while installing the case half. 3. While holding the governor shaft fork against the input shaft bearing, place the right (top) casing onto the left casing half. Page C-8 Transaxle Shop Rebuild and Parts ManualTRANSAXLE REASSEMBLY Clutch Side Casing Halt Fig. C-21 Transaxle Case Assembly and Shifter Detent Install the Shifter Detent 1. Install the ball (4) and then the spring (5) as shown (Ref Fig. C-21 on page C-9). 2. Install the bolt (6) using a 14mm socket and tighten to specified torque. Install the Transaxle Casing Bolts The two casing bots that also attach the accel: NOTE) sor bracket fo the casing are longer than the ‘other six, and are installed in the opposite direction. 1. Install the two accelerator bracket/transaxle cas- ing bolts (1, 2) with lock washers (3), and two nuts (4) each, in the positions and direction shown. Do not tighten them (Ref Fig. C-22 on page C-9). (Late production) aN (Early production) &\ Fig. C-22 Casing Bolts and Axle Tube Installation 2. Install four casing bolts (5), with lock washers (3) and nuts (4) in the positions and direction shown. Do not tighten them. 3. Position the shifter cable mounting bracket (6) and install two casing bolts (5), with lock wash- ers (3) and nuts (4) as shown. lezen) Transaxle Shop Rebuild and Parts Manual Page C-9TRANSAXLE REASSEMBLY 4. Using a 12mm socket and 12mm wrench, tighten the transaxle casing bolts to specified torque in ‘two stages, in the order shown (Ref Fig. C-23 on page C-10). Shifter cable ‘mounting bracket Follow numbers to tighten casing bolts, in proper sequence. Tighten to specified torque in two stages. Fig. C-23 Torque Sequence Install the Right Side Axle Tube on the Transaxle Casing 1. Position the axle tube (7) on the mounting studs in the casing and install five nuts (8) with lock washers(9). Tighten nuts to specified torque (Ref Fig. C-22 on page C-). Install the Right Side Axle Shaft Ifthe ae shaft bearing has not been installed NOTE ‘on the axle shaft, use a mechanical press to instal a new one before instaling the shat ino the ransaie 1. Lubricate the axle shaft (10) and carefully insert it through the axle tube and into the transaxle cas- ing, short spline end first (Ref Fig. C-22 on page C9). 2. Gently rotate the shaft until it meshes with the transaxle gearing and drops into place, seating the axle shaft bearing against the inner axle tube retaining ring (Ref Fig. C-24 on page C-10). 3. Use snap ring pliers to install the outer axle tube retaining ring (11)(Ref Fig. C-22 on page C-8). Shaft Bearing _ 4 = | Inner Retaining Ring Fig. C-24 Axle Shaft Installation Attach the Brake Assembly to the Axle Tube 1. Position the brake assembly (1) on the axle tube as shown (Ref Fig. C-25 on page C-10). Fig. C-25 Brake Assembly Installation 2. Install four new bolts (2) and lock nuts (3) using a 1/2" socket and tighten to specified torque. Page C-10 Transaxle Shop Rebuild and Parts Manual lezen)TRANSAXLE REASSEMBLY Apply Anti-Seize Compound 1. Apply an anti-seize compound (Neverseize) to ‘the axle shaft splines and install the washer (4) and brake drum (5) onto the axle shaft and brake assembly in the same manner described for the left side (Ref Fig. C-25 on page C-10). EERE att”2 9207 an at-seize compound (Neverseize) to the axle shaft splines ‘may make future removal of the brake drum difficult, possibly ‘causing damage to the drum. Axle Nut Installation 1. Install the cup washer (6) (if used), spacer (7), axle nut (8), and cotter pin (9) on the axle shaft as shown (Ref Fig. C-25 on page C-10). Tighten axle unit to specified torque. TIGHTENING TORQUE DESCRIPTION kg/em Nim ft/lb RING GEAR / CARRIER HOUSING BOLTS 550-690 | 390-617 | 398-456 GOVERNOR FORK SCREW 14-18 tate | 1.048 GOVERNOR PLATE SCREW 14-18 1418 | 10-13 TRANSAXLE CASING NUTS/ BOLTS 210-260 | 206-255 | 152-188 SHIFTER DETENT SOLT se0-210 | 157-206 | 116-152 OIL DRAIN PLUG 210-260 | 206-255 | 152-188 [AXLE TUBE MOUNTING NUTS 350-430 | 343-422 | 253-313 AXLE NUT 970-2000 | 95-225 | 70-166 énm_| 60-80 59-78 | 43-58 omens anm | 140-00 | 137-176 | 101-130 Fig. C-26 Torque Specifications (Wet) Transaxle Shop Rebuild and Parts Manual Page C-11| TRANSAXLE REASSEMBLY Notes: Page C-12 Transaxle Shop Rebuild and Parts Manual4-CYCLE TRANSAXLE D 4-CYCLE TRANSAXLE ILLUSTRATED PARTS BREAKDOWN (Er) Transaxle Shop Rebuild and Parts Manual Page DiGasoline Vehicle 4-CYCLE TRANSAXLE ep IyeA Jo wos (0ye19 o1nNesPAH) Transaxle Shop Rebuild and Parts Manual Page D-14-CYCLE TRANSAXLE Gasoline Vehicle | 4. ne el (so4e1a ne104H) ‘e580 au} Jo WoHoq ‘9uy uo ypied ured yoeIa & ‘fq paveojput S| uoIsien “Ht ‘27 IYeA Jo WoL a 801 - $01 Sway} SepNIOU| - FOL {92 =S Sw} SapnIDUI - pz 29 v9 Swill sepnyouI - Eg Page D-2 Transaxle Shop Rebuild and Parts Manuall4-CYCLE TRANSAXLE Gasoline Vehicle When ordering parts, please speciy the model and serial number ofthe product. “Indicates a component that is not availabe as an indvidual part "Indicates consult Customer Service Department for addtional information em | pantno.| 1 2 3 4 5 DESCRIPTION ary. 1 | se | REAR AXLE ASSEMBLY (SEE SERVICE PARTS MANUAL FOR SPECIFIC PART NUMBER FOR YOUR MAKE AND MODEL VEHICLE) 1 2 26760-G01 CASE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 3-12) 1 3 | 26762-G01 OWL SEAL 1 4 | 26763-G01 SNAP RING. 1 5 | 26760-Go1 SPACER 1 6 | 26765-c01 SELECTOR SHAFT 1 7 72259-G01 OIL SEAL...... 1 a | 26767-G01 STUD (EARLY PRODUCTION) 5 9 26828-G01 LOCK WASHER, 10MM (EARLY PRODUCTION). 5 10 26829-G01 NUT, M10 X 1.5MM (EARLY PRODUCTION)...... 5 11 | 72260-G01 BOLT, M10 X 1.5 X 23MM (LATER PRODUCTION) 5 12 26761-G01 OIL SEAL 1 13, | 26768-c01 OIL CHECK PLUG. 1 14 | 26769-G01 GASKET, 8M 1 15 26770-G01 OIL DRAIN PLUG... 1 16 | 26771-cG01 GASKET, 14MM 1 17 26772-G01 OIL PLUG FILLER.......... 1 1a | ersten DRIVER SIDE AXLE TUBE (SEE SERVICE PARTS MANUAL FOR SPECIFIC PART NUMBER FOR YOUR MAKE AND MODEL VEHICLE) (INCLUDES ITEMS 19-20), 1 19 26814-G01 ‘SNAP RING, 52MM (MECHANICAL BRAKE) 2 20 | 33687-G01 ‘SNAP RING, 62MM (HYDRAULIC BRAKE) 1 at 22 23 | 26779-G01 INPUT SHAFT (INCLUDES ITEMS 24 - 28) 1 24 26778-G01 SCREW AND WASHER...... 2 25 | 26780-Go1 GOVERNOR BASE... 1 26 | 26781-Go1 LOCK PIN. 1 27 26782-G01 GOVERNOR PLATE UNIT... 1 28 | 26783-G01 BALL BEARING 1 Page D-3 Transaxle Shop Rebuild and Parts Manual (EZGo)Gasoline Vehicle 4-CYCLE TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Ingicates a component that is not available as an individual par. "Indicates consult Customer Service Department for additional information mem | paRTNo. | 1 2 3 4 5 DESCRIPTION ary. 29 | 26815-G01 SHIFTER CABLE BRACKET. 1 30 26784-G01 GOVERNOR SLEEVE......... 1 a1 | 26785-Go1 BALL BEARING 1 32 3 34 35 seanenenane DRIVER SIDE AXLE SHAFT ASSEMBLY (SEE SERVICE PARTS MANUAL FOR SPECIFIC PART NUMBER FOR YOUR MAKE AND MODEL VEHICLE) (INCLUDES ITEMS 36-39) see 1 36 | 26811-co1 BALL BEARING (MECHANICAL BRAKE) 1 37 33686-G01 BALL BEARING (6206DD) (HYDRAULIC BRAKE) 2 38 72267-G01 ‘SNAP RING, 30 MM (HYDRAULIC BRAKE)....... 1 39 | 72268-Go1 COLLAR (303828) (HYDRAULIC BRAKE) 1 40 41 42 | 26797-G01 SPACER 3 43 | 26708-G01 GEAR, 34 TOOTH 1 44 | 26799-G01 COUNTER SHAFT. 1 45 46 | 26800-Go1 DIFFERENTIAL CASE (INCLUDES ITEMS 47 - 51) 1 47 26801-G01 ‘SIDE DIFFERENTIAL GEAR.......... 2 48 26802-G01 DIFFERENTIAL PINION: 2 49 | 26803-Go1 DIFFERENTIAL SHAFT 1 50 26804-G01 SPRING PIN......... 1 51 | 26806-Gor BALL BEARING (6007). 1 52 53 54 | 26852-Go1 GEAR, 59 TOOTH (H.P. VERSION) (INCLUDES ITEM 56). 1 55 26807-G01 GEAR, 62 TOOTH (INCLUDES ITEM 56)......... 1 56 | 26806-Go1 BALL BEARING (6007) 1 87 Ga Transaxle Shop Rebuild and Parts Manual Page D-44-CYCLE TRANSAXLE Gasoline Vehicle When ordering parts, please speciy the model and serial number ofthe product. “Indicates a component that is not availabe as an indvidual part "Indicates consult Customer Service Department for addtional information em | pantno.| 1 2 3 4 5 DESCRIPTION 58 26808-G01 BOLT, M10 X 1.25 X 26MM LG 59 26792-G01 COLLAR, 24 X 12........ 60 | 25796-Go1 BALL BEARING (6304)... 61 26795-G01 SPACER 62 26785-G01 BALL BEARING............. 63 | 26810-G01 PASSENGER SIDE AXLE SHAFT ASSEMBLY (SEE SERVICE PARTS MANUAL FOR SPECIFIC PART NUMBER FOR YOUR MAKE AND MODEL VEHICLE) (INCLUDES ITEMS 64/66 OR 65/67). 64 26811-GO1 BALL BEARING (MECHANICAL BRAKE) 65 | 33686-Go1 BALL BEARING (6206DD) (HYDRAULIC BRAKE) 66 72267-G01 ‘SNAP RING, 30 MM (HYDRAULIC BRAKE)....... 67 | 72268-Go1 COLLAR (303828) (HYDRAULIC BRAKE) 68 | 26786-Go1 SPACER 20 x 22 69 27123-G01 CLUTCH PIN... a 70 | 26790-G01 CENTER SHAFT 7 | 27122-¢01 GEAR, 55 TOOTH 7” 73 74 seenenenanes PASSENGER SIDE AXLE TUBE ASSEMBLY (SEE SERVICE PARTS. MANUAL FOR SPECIFIC PART NUMBER FOR YOUR MAKE AND MODEL VEHICLE) (INCLUDES ITEMS 75 OR 76)............- 75 | 26814-Go1 SNAP RING, 52MM 76 33687-G01 ‘SNAP RING, 62MM (HYDRAULIC BRAKE)........ 7 78 | 26788-Go1 SPACER. 79 26793-G01 GEAR, 16 TOOTH......... 80 26832-G01 SHIFTER SHAFT. 81 26817-G01 DOWEL PIPE... 22 | 26851-Gor GEAR, 19 TOOTH (HP VERSION) 83 26818-G01 STEEL BALL 84 26819-G01 SPRING....-.cccseseeee os Page D-5 Transaxle Shop Rebuild and Parts Manual (EZGo)Gasoline Vehicle 4-CYCLE TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Ingicates a component that is not available as an individual par. "Indicates consult Customer Service Department for additional information mem | paRTNo. | 1 2 3 4 5 DESCRIPTION ary. 85 26820-G01 BOLT, M10 X 1.25 X 12MM. 1 86 26775-G01 GOVERNOR SHAFT. 1 a7 | 72261-Go1 COLLAR, 20 X8 1 88 | 26822-G01 CASE GASKET 1 89 26823-G01 BOLT, M8 X 1.25 X 100MM....... 8 90 26824-G01 BOLT, M8 X 1.25 X 110MM. 1 ot 72264-G01 BOLT, M8 X 1.25 X 115MM. 1 92 | 26826-Go1 LOCK WASHER, 8MM 12 93 | 26827-Go1 NUT, M8 X 1.25MM 12 94 95 96 26828-G01 LOCK WASHER, 10MM (EARLY PRODUCTION)...... 5 97 | 26829-Go1 NUT, M10 X 1.5MM (EARLY PRODUCTION) 5 98 99 26776-G01 GOVERNOR FORK. 1 100 | 26777-G01 GOVERNOR STOPPER 1 101 26778-G01 SCREW AND WASHER. 2 102 | 26831-G01 GASKET. 1 103 | 27124-G01 GEAR, 47 TOOTH 1 104 26773-G01 PASSENGER SIDE CASE ASSEMBLY (INCLUDES ITEMS 105 - 108)... 1 105 | 72259-G01 OIL SEAL 1 106 26767-G01 ‘STUD, M10 X 1.5 X 40MM (EARLY PRODUCTION)... 5 107 | 72260-G01 BOLT, M10 X 1.5 X23MM (LATER PRODUCTION) 5 108 | 26774-G01 OIL SEAL, 10 X 20x 4. 1 Ga Transaxle Shop Rebuild and Parts Manual Page D-64-CYCLE TRANSAXLE Gasoline Vehicle Notes: Page D-7 Transaxle Shop Rebuild and Parts Manual0 GESEEICompany E-Z-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material ‘This manual may not be reproduced in whole oF in part without the express permission of E-Z-GO Division of Textron Inc, Technical Communications Department