EZGO 628519 FUJI TRANSAXLE for Kawasaki Engine Applications Service Manual

Shop Rebuild and Service Parts Manual FUJI TRANSAXLE for Kawasaki Engine Applications

628519 ISSUED MARCH 2013

SHOP REBUILD AND SERVICE PARTS MANUAL

FUJI TRANSAXLE for Kawasaki Engine Applications

STARTING MODEL YEAR 2013

E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously.

The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.

E-Z-GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page i

NOTES

Notes:

Page ii

INTRODUCTION Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

HOW TO USE THIS MANUAL This manual is designed to suit the needs of mechanics at all levels of experience with the Fuji Transaxle. The outline format will allow the mechanic to choose the level of instructional detail needed to completely disassemble, diagnose, repair/overhaul, and reassemble the transaxle.

The manual is divided into four major operational sections, 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.

1.Remove and inspect/replace one axle shaft and/or axle shaft bearing.

2.Remove and inspect one axle tube.

3.Inspect/replace one axle oil seal in the transaxle casing.

4.Remove and inspect/replace the input shaft, shifter shaft, and governor shaft oil seals. These components must be removed in order to inspect oil seals.

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 disassemble 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: We strongly recommend that no matter what your experience level, you use this manual as a guide when disassembling, repairing/overhauling, and reassembling the transaxle. Before working on the transaxle, read the text and, in particular, each WARNING, CAUTION, and NOTICE. Some illustrations may show components that differ from your transaxle. This is the result of ongoing improvements to the transaxle design.

WARNINGS, CAUTIONS, AND NOTICES Throughout this manual, the following WARNINGS, CAUTIONS, and NOTICES are used. For the protection of all personnel and the vehicle, be aware of and observe the following:

A WARNING indicates a hazardous condition that could result in serious injury or death.

A CAUTION indicates a condition that may result in damage to the vehicle or surrounding facilities.

NOTICE A NOTICE indicates a condition that should be observed.

IMPORTANT SAFETY WARNINGS In any product, components will eventually fail to perform properly as the result of normal use, age, wear, or abuse.

It is virtually impossible to anticipate all possible component 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 therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, 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 component should move unexpectedly.

Some components are heavy, spring-loaded, highly corrosive, and 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 if 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.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page iii

INTRODUCTION Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area.

Before working on vehicle, remove all jewelry (watch, rings, necklaces, etc.).

Be sure that no loose clothing or hair can contact moving parts.

Wear eye protection when working on or around vehicle. In particular, use care when working around batteries, or when using solvents or compressed air. se care not to contact hot objects.

Before attempting to operate or adjust the power train, 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 circuit.

When connecting battery cables, pay particular attention to the polarity of the battery terminals. Never confuse the positive and negative cables.

Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.

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.

Exhaust gas (carbon monoxide) is deadly.

Carbon monoxide is an odorless gas that is formed as a natural part of the incomplete combustion of hydrocarbon 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

If experiencing any of these symptoms, get fresh air immediately.

Never test the ignition system without either connecting the spark plug lead to a tester or spare grounded spark plug.

If the 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 of a 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 SYSTEM 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.

Never operate the starter with the spark plugs removed unless the ignition system has been disabled 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.

Page iv

Fuji Transaxle Shop Rebuild and Service Parts Manual

TABLE OF CONTENTS SECTION

PAGE No.

SAFETY ................................................................................................................................................................... Inside Covers GENERAL INFORMATION ............................................................................................................................................................II INTRODUCTION ...........................................................................................................................................................................III

SECTION

PAGE No.

TRANSAXLE DISASSEMBLY ...................................................................................................................................................... A Wheel Brake Removal....................................................................................................................................................... A-1 Axle Shaft and Axle Tube Removal ................................................................................................................................... A-2 Shifter Detent Assembly Removal ..................................................................................................................................... A-2 Transaxle Case Separation ............................................................................................................................................... A-3 Transaxle Case Disassembly ............................................................................................................................................ A-4 Select Shift Assembly Removal......................................................................................................................................... A-4 INSPECTION OF PARTS.............................................................................................................................................................. B Oil Seal Inspection ............................................................................................................................................................ B-1 Bearing Inspection ............................................................................................................................................................ B-1 Transaxle Case Inspection ................................................................................................................................................ B-1 Gear Teeth Inspection....................................................................................................................................................... B-1 TRANSAXLE REASSEMBLY ....................................................................................................................................................... C Select Shift Assembly Installation ..................................................................................................................................... C-1 Governor Gear .................................................................................................................................................................. C-2 Governor Gear Removal ................................................................................................................................................... C-2 Governor Gear Installation ................................................................................................................................................ C-2 Transaxle Case Assembly................................................................................................................................................. C-3 Transaxle Case Installation ............................................................................................................................................... C-5 Shifter Detent Assembly Installation.................................................................................................................................. C-6 Axle Shaft and Axle Tube Installation ................................................................................................................................ C-6 Brake Assembly Installation .............................................................................................................................................. C-7

ILLUSTRATED PARTS BREAKDOWN ........................................................................................................................................ D Model 627892 - GAS REAR AXLE .................................................................................................................................... D-2 Model 627891 - ED58BA02 GAS REAR AXLE.................................................................................................................. D-6 Model 617488 - FUJI WITH LSD GAS REAR AXLE........................................................................................................ D-10

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page v

TABLE OF CONTENTS

NOTES:

Page vi

Fuji Transaxle Shop Rebuild and Service Parts Manual

TRANSAXLE DISASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TRANSAXLE DISASSEMBLY Tool List

the transaxle. If the brakes need to be removed for maintenance, follow the following procedure.

Qty.

Extension, 4", 3/8"-drive ............................................. 1 Small diameter pickup magnet.................................... 1 Rubber mallet, medium ............................................... 1 Snap ring pliers, medium ............................................ 1 Snap ring pliers, small................................................. 1 Standard pliers ............................................................ 1 Seal puller ................................................................... 1 Ratchet, 3/8"-drive ...................................................... 1 Ratchet, 1/2”-drive ...................................................... 1 Flat-blade screwdriver, small ...................................... 1 Phillips screwdriver, #2................................................ 1 Wrench, 12-mm........................................................... 1 Socket, 12-mm, 3/8"-drive........................................... 1 Socket, 14-mm, 3/8"-drive........................................... 1 Socket, 17-mm, 3/8"-drive........................................... 1 Socket, 1/2", 3/8"-drive................................................ 1 Socket, 1 1/8", 1/2"-drive............................................. 1 Socket, 15/16", 1/2"-drive............................................ 1 Combination wrench, 1/2" ........................................... 1 Lug wrench, 3/4" ......................................................... 1

Brake removal will vary between models and mechanical or hydraulic brakes. Typical mechanical brakes are shown.

Please refer to the Repair and Service Manual for your specific brake removal procedure.

1. Attach a wheel and tire to the brake hub on the driverside axle tube and stand the transaxle on end with the wheel as a base.

Keep work area clean and well-organized while performing the operations described in this manual. This will help prevent accidents and reduce the possibility of mistakes that could damage or impair the performance of the transaxle.

Some mating parts with wear surfaces were machined together when the transaxle was manufactured and have established wear patterns during operation. The reassembly of parts in their original positions and orientations, with their original mating parts, is critical to the performance and life expectancy of the transaxle. Mark and sort all parts as they are disassembled, so that they will be reassembled and installed in their original positions.

2. Remove the cotter pin (1) and, using a 1 1/8" socket, remove axle nut (2), washer (3), and cup washer (4) (if present) from the axle shaft (10).

3. Pull the brake drum (5) from the backing plate (6), and remove the washer (7).

2

3

4

5

7

6 10

11

Wheel Brake Removal

NOTICE

1

8

9

The axle shaft, axle tube, and wheel brake can be removed as an assembly to perform maintenance on

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page A-1

TRANSAXLE DISASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

NOTICE When the vehicle was manufactured, an antiseize compound was applied to the axle shaft splines to prevent the brake drum from bonding to the shaft. If the brake drum has since been removed and reinstalled without an antiseize compound, removal of the drum may require the use of a slide hammer.

5. Using a seal puller, remove the case seals (7) from the transaxle case (6).

5

1 2

3 7

4. Using a 1/2" socket, remove the four bolts (8) and nuts (9) and detach the backing plate (6) from the axle tube (11).

5. Repeat process to remove other brake assembly.

4

6

Axle Shaft and Axle Tube Removal

2

NOTICE The axle shaft and axle tube do not need to be removed to perform maintenance on the transaxle. If the axle shaft or axle tube are in need of maintenance, perform the following procedure.

It is assumed that the wheels have been removed, the oil drained from the transaxle, and that the transaxle has been removed from the vehicle. If these things have not been done, do so before continuing with this section. Refer to the Repair and Service Manual of the specific vehicle for information and safety considerations when removing the transaxle.

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, discolored, or that rotate roughly or noisily.

1. Using snap ring pliers, remove the bearing retaining ring (1) from the end of the axle tube (2).

2. Carefully pull the axle shaft (3) and bearing (4) out of the axle tube (2).

Do not scratch, score, or damage the seal bore in any way. This could cause the seal to fail.

Shifter Detent Assembly Removal 1. Using a 14-mm wrench, remove the shifter detent bolt and gasket.

3. Using a 14-mm socket, remove five bolts (5) and the axle tube (2) from the transaxle case (6).

4. Repeat steps to remove the axle shaft and axle tube from other side of the transaxle case (6).

The axle shaft and tube can be removed as an assembly for (7) case seal replacement.

Page A-2

Fuji Transaxle Shop Rebuild and Service Parts Manual

TRANSAXLE DISASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

2. Using a small magnet, remove the spring and steel ball from the shifter detent bolt hole.

B

transaxle so that the input shaft side is up.

3. Grip the transaxle case and pull up while gently tapping on the case until it separates.

Transaxle Case Separation

4. Gently tap on the input shaft to relieve shaft from bearing.

NOTICE Mark any nut or bolt location where brackets and braces are located prior to removal.

Make note of the direction the case bolts are installed in the case prior to removal. Case bolts are to be reinstalled in the same direction from which they were removed.

1. Using a 12-mm wrench and socket, remove 10 transaxle case nuts and bolts.

5. Carefully separate the transaxle case halves.

2. Using a wooden or rubber mallet, gently tap around the transaxle case joint to loosen the seal. Orient the

6. Remove two transaxle case alignment dowels and gasket.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page A-3

TRANSAXLE DISASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

Transaxle Case Disassembly

4. Remove input shaft oil seal from transaxle case.

1. Remove input shaft assembly.

Select Shift Assembly Removal 1. Remove select shift assembly seal.

NOTICE The three assemblies can be removed at the same time.

2. Remove center shaft assembly, carrier assembly, and shift shaft assembly.

2. Using small snap ring pliers, remove snap ring from select shift shaft.

3. Remove the counter shaft assembly.

3. Remove select shift shaft from transaxle case.

Page A-4

Fuji Transaxle Shop Rebuild and Service Parts Manual

INSPECTION OF PARTS Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

INSPECTION OF PARTS

NOTICE We strongly recommend that all parts found to be damaged be replaced.

Transaxle Case Inspection 1. Perform visual inspection of inside of transaxle case for contact with gear teeth. Replace as necessary.

Gear Teeth Inspection 1. Perform visual inspection of gears of all assemblies (input shaft assembly, center shaft assembly, differential case assembly, and counter shaft assembly) for unusual wear patterns and chipped, broken, or missing teeth. Replace as necessary.

All parts must be thoroughly cleaned and free of all dirt, oil, grease, or residue 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 in this section.

Oil Seal Inspection

NOTICE It is recommended that any oil seals that are removed (and all seals, if a transaxle is more than one year old when disassembled) be replaced with new ones.

1. Perform visual inspection of all oil seals for damage of any kind. Replace as necessary.

Bearing Inspection

NOTICE Remove press-fit bearings only if they are damaged, excessively worn, or if it is necessary in order to remove other parts.

It is recommended that removed press-fit bearings be replaced with new ones.

1. Perform visual inspection of all bearings for damage and excessive wear. Replace bearings that are pitted, nicked, burred, discolored, or that rotate roughly or noisily.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page B-1

INSPECTION OF PARTS Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Page B-2

Fuji Transaxle Shop Rebuild and Service Parts Manual

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TRANSAXLE REASSEMBLY Tool List

to specified torque on the second pass.

Qty.

Extension, 4", 3/8"-drive ............................................. 1 Ball peen hammer, small............................................. 1 Seal installer................................................................ 1 Rubber mallet, medium ............................................... 1 Snap ring pliers, medium ............................................ 1 Snap ring pliers, small................................................. 1 Standard pliers ............................................................ 1 Mechanical press ........................................................ 1 Nonferrous punch, medium......................................... 1 Nonferrous punch, small ............................................. 1 Ratchet, 3/8"-drive ...................................................... 1 Ratchet, 1/2”-drive ...................................................... 1 Flat-blade screwdriver, medium .................................. 1 Phillips screwdriver, #2................................................ 1 Wrench, 12-mm........................................................... 1 Socket, 12-mm, 3/8"-drive........................................... 1 Socket, 14-mm, 3/8"-drive........................................... 1 Socket, 17-mm, 3/8"-drive........................................... 1 Socket, 1/2", 3/8"-drive................................................ 1 Socket, 1 1/8", 1/2"-drive............................................. 1 Socket, 15/16”, 1/2"-drive............................................ 1 Combination wrench, 1/2" ........................................... 1 Lug wrench, 3/4" ......................................................... 1 Torque wrench, 3/8"-drive ........................................... 1 Straight-blade screwdriver .......................................... 1

NOTICE Fasteners that are plated or lubricated when installed are considered ”wet” and require approximately 80 percent of the specified torque for ”dry” fasteners. All transaxle fasteners are considered ”wet”.

NOTICE Because assemblies of moving parts establish wear patterns together, it is recommended that all parts of an assembly be replaced if one part is found to be damaged. Noise levels during operation may be increased if only individual parts are replaced.

Select Shift Assembly Installation

NOTICE Make sure the governor gear shaft assembly is in the correct position before installing the gear assemblies.

1. Lubricate the shaft with assembly lube (molybdenum disulfide) and install the select shift shaft into the transaxle case.

Prior to transaxle reassembly, all parts must be thoroughly cleaned and free of dirt, oil, grease, or residue of any kind; free of nicks, burrs, or damage of any kind to wear surfaces; and inspected for excessive wear. Parts that are damaged or are not within dimensional specifications should be replaced.

Some mating parts with wear surfaces were machined together when the transaxle was manufactured and have established wear patterns during operation. The reassembly of transaxle parts in their original positions and orientations with their original mating parts is critical to the performance and life expectancy of the transaxle.

2. Using small snap ring pliers, install snap ring onto select shift shaft.

Make sure all threaded surfaces are clean and free of gasket material/residue.

When tightening a number of screws or bolts in a given pattern, tighten them in two stages. Tighten them to 1/2 of specified torque in one pass through the pattern, then

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page C-1

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

3. Install new select shift assembly seal.

Remove the thrust bearing and washers from their recess in the transaxle case around the governor gear shaft hole.

Governor Gear The Fuji transaxle utilizes a gear driven, speed activated, centrifugal weight system to regulate the speed of the vehicle.

Governor Gear Removal

On one side of the governor gear, use a small punch to push aside the tab securing the centrifugal weight retaining pin. While holding the tab aside, have an assistant push the pin out of the gear and remove the weight.

Once the input shaft, center shaft, carrier, shift shaft and counter shaft assemblies have all been removed from the transaxle case, the governor gear assembly is exposed for removal.

NOTICE Take note of the position and orientation of the components to aid in re-assembly.

Rotate the governor shaft away from the governor gear.

Repeat the above step to remove the other centrifugal weight.

From the outside of the transaxle case, locate the governor gear shaft hole. Using a punch and a mallet, carefully tap out the governor gear shaft and remove the governor gear assembly.

Page C-2

Fuji Transaxle Shop Rebuild and Service Parts Manual

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

With the centrifugal weights removed, the governor sleeve can be removed, exposing the governor gear shaft.

Place the assembled governor gear so that the governor gear shaft is aligned with the hole in the thrust bearing/ washers and the governor gear shaft hole in the case. using a rubber mallet, carefully tap the governor gear assembly into its hole in transaxle case.

Use a punch to drive the governor gear shaft from the governor gear.

Governor Gear Installation Clean and lubricate the governor gear shaft.

Re-install the centrifugal weights into their notches in the governor gear and secure with their pins. Push the pins until the heads of the pins snap into place.

Check that the gear, centrifugal weights and governor sleeve all move and rotate freely. Rotate the governor shaft onto the governor gear before continuing assembly of the transaxle.

Transaxle Case Assembly

If using press to install seals, adequately support the aluminum casing as close to the seal bore as possible.

Failure to do so could result in a fractured casing.

NOTICE It is recommended that any oil seals that were removed, and all seals if a transaxle is more than one year old when disassembled, be replaced with new seals.

Clean and lubricate the thrust bearing and washers.

Place the washer, bearing and washer (in that order) into the recess in the case around the governor gear shaft hole in the transaxle case.

To prevent damaging the governor sleeve, use a rubber mallet with care to tap the governor gear assembly into its hole in transaxle case.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page C-3

B

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

1. Install input shaft oil seal in transaxle case. Lubricate seal with assembly lube (molybdenum disulfide) before installing.

2. Install the counter shaft assembly.

NOTICE NOTICE Make sure the governor gear assembly is in the correct position prior to installing the counter shaft.

Lubricate the center shaft assembly, carrier assembly, shift shaft assembly, and input shaft assembly with assembly lube prior to installation.

Align the center shaft assembly, carrier assembly, and shift shaft assembly as noted during disassembly. Ensure the shift shaft assembly is properly seated in the race of the center shaft assembly.

NOTICE Lubricate the counter shaft with assembly lube prior to installation.

Page C-4

Fuji Transaxle Shop Rebuild and Service Parts Manual

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

3. Install the center shaft assembly, carrier assembly, and shift shaft assembly into the transaxle case.

4. Install the input shaft assembly.

5. It is possible that the assemblies and bearings have not completely seated. Slowly rotate the transaxle components and check for meshing prior to putting the transaxle case together.

Transaxle Case Installation

3. Align transaxle cases making sure that the input shaft is properly seated through the bearing of the case.

Do not use bolts to force the case halves together. Make sure the case halves are properly seated prior to bolt installation.

1. Install two transaxle case alignment dowels.

2. Install transaxle case gasket.

NOTICE Carefully align the slot in the select shift assembly with the peg on the shift shaft assembly before assembling the two transaxle case halves.

NOTICE Install case bolts in the same direction as noted during removal.

Tighten the case bolts in a cross pattern to prevent case distortion.

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page C-5

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

B

4. Using a 12-mm wrench and socket, install 10 transaxle case bolts and nuts. Tighten to a torque of 15.2 to 18.8 ft.lb (20.6 to 25.5 Nm).

2. Using a 14-mm socket, install the axle tube (2) on the transaxle case (6) with five bolts (5). Tighten to 34.3 to 42.2 ft.lb (46.5 to 57.2 Nm).

Carefully install and rotate the axle shaft and bearing making sure it is properly seated with the gears of the transaxle prior to installing retaining ring in axle shaft.

3. Install the axle shaft (3) and bearing (4) into the axle tube (2).

4. Using snap ring pliers, install the bearing retaining ring (1) in the end of the axle tube (2).

Shifter Detent Assembly Installation 1. Install steel ball and spring into shifter detent bolt hole.

5. Repeat steps to install the axle shaft (3) and axle tube (2) to the other side of the transaxle case (6).

5

1 2

3 7

2. Using a 14-mm wrench, install the shifter detent bolt and washer. Tighten to 16.7 to 20.6 ft.lb (11.6 to 16.2 Nm)

Axle Shaft and Axle Tube Installation 1. If removed, install the case seals (7) into the transaxle case (6).

Page C-6

Fuji Transaxle Shop Rebuild and Service Parts Manual

4

6 2

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Brake Assembly Installation

2

3

4

5

aligned with the hole in the axle (10), continue tightening [70 to 140 ft.lb (95 to 190 Nm)] until they are aligned.

6

7

10

11

9. Install a new cotter pin (1) through the nut slot (2) and axle hole (10) and bend the ends back to secure it.

10. Repeat the steps to install the other brake assembly.

1

9

8

1. Position the backing plate (6) on the axle tube mounting plate (11).

2. Using a 1/2” socket, install the backing plate (6) to the axle tube (11) using four new bolts (8) and four new lock nuts (9).Tighten the bolts to 23 to 28 ft.lb (31 to 38 Nm).

3. Install the washer (7) as shown.

Failure to apply an anti-seize compound (Neverseize) to the axle shaft splines may make future removal of the brake drum difficult, possibly causing damage to the drum.

4. Lubricate the axle splines (10) with Neverseize.

NOTICE (For NSI/older style brakes) Insert a straight-blade screwdriver between the adjusting lever and the adjusting mechanism. Rotate the star wheel counterclockwise until the shoes have retracted enough to allow the brake drum to be installed.

(For Bendix/newer style brakes) Carefully lift 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 to 15 ‘clicks’.

5. Slide the brake drum (5) into position.

6. Install the brake drum (5) onto the backing plate (6) and axle assembly.

7. Install cup washer (4) (if used) and washer (3).

8. Using a 1 1/8" socket, install the axle nut (2) to at least 70 ft.lb (95 Nm). If the slot in the axle nut (2) is not

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page C-7

B

TRANSAXLE REASSEMBLY Read all of each Section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Page C-8

Fuji Transaxle Shop Rebuild and Service Parts Manual

FUJI TRANSAXLE

FUJI TRANSAXLE for Kawasaki Engine Applications ILLUSTRATED PARTS BREAKDOWN

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-1

FUJI TRANSAXLE

63

DETAIL A

9

60

5

10

11

7

24

56

9

28 29

27 38

37

6

8

3

4

30 64

39

31 40

61

41 42

69

43

16

65 15

14

44 36 37

66 19

13 12 DETAIL A

32

2

53

33 35 32 48

52

50

67

23 55

70

52

64 62

68

17 49 51

12

46 20

1 CASE L COMPLETE, AXLE ASSY includes items 3 - 12, 24 17 CASE R COMPLETE, AXLE ASSY includes items 12, 19 - 23

21

45 DIFFERENTIAL ASSY includes items 46, 53 & 55

22

26

46 DIFFERENTIAL CASE ASSY includes items 47 - 52 47 DIFFERENTIAL GEAR SET includes items 48 & 49 53 GEAR 60 COMPLETE includes item 52

58 60

56 AXLE SHAFT L COMPLETE ASSY includes item 60 58 AXLE SHAFT R COMPLETE ASSY includes item 60

Page D-2

Fuji Transaxle Shop Rebuild and Service Parts Manual

63

73

63 25

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

MODEL 627892 - GAS REAR AXLE 1

628561

CASE L COMPLETE , AXLE (INCLUDES ITEMS 3 - 12, 24).............................

1

3

628148

GOVERNOR GEAR, COMPLETE...............................................................

1

4

628150

GOVERNOR SLEEVE.................................................................................

1

5

607904

FLAT WASHER ...........................................................................................

2

6

607905

THRUST BEARING.....................................................................................

1

7

607907

GOVERNOR GEAR SHAFT........................................................................

1

8

607910

GOVERNOR SHAFT...................................................................................

1

9

607909

FLAT WASHER, 6 MM ................................................................................

2

10

607911

OIL SEAL, 6 x 10 x 2.5 MM .........................................................................

1

11

607913

RETAINING RING E5 ..................................................................................

1

12

72259G01

OIL SEAL, 28 x 47 x 9 MM ..........................................................................

3

13

26818G01

STEEL BALL .......................................................................................................

1

14

26819G01

SPRING ..............................................................................................................

1

15

26831G01

GASKET, 10 ........................................................................................................

1

16

26820G01

FLANGED BOLT, M10 x 1.25 x 12 MM LG .........................................................

1

17

607942

CASE R COMPLETE, AXLE (INCLUDES ITEMS 12, 19 - 23) ...........................

1

19

607914

SELECT SHAFT, COMPLETE ....................................................................

1

20

607915

OIL SEAL, 13 x 22 x 5MM ...........................................................................

1

21

607916

SNAP RING, 13 MM ....................................................................................

1

22

607917

SPACER, 13 x 1 MM ...................................................................................

1

23

607918

SPRING PIN................................................................................................

1

24

607919

AIR BREATHER ..........................................................................................

1

25

26770G01

OIL DRAIN PLUG ...............................................................................................

2

26

26771G01

GASKET, 14 ........................................................................................................

2

27

26785G01

BALL BEARING (6204).......................................................................................

1

28

607921

GOVERNOR GEAR, 34 ......................................................................................

1

29

607920

PIN, 6 x 12L ........................................................................................................

1

30

628151

INPUT SHAFT.....................................................................................................

1

2

18

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-3

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

31

607922

BALL BEARING (62/28) .....................................................................................

1

32

607923

BALL BEARING (TMB202).................................................................................

2

33

628153

COUNTER SHAFT .............................................................................................

1

35

628154

GEAR, 33 ...........................................................................................................

1

36

26786G01

SPACER, 20 x 2.2 MM .......................................................................................

1

37

26796G01

BALL BEARING (6304) ......................................................................................

2

38

72261G01

COLLAR, 20 x 8 MM ..........................................................................................

1

39

628156

GEAR, 18 ...........................................................................................................

1

40

26792G01

COLLAR, 24 x 12 MM ........................................................................................

1

41

628158

GEAR, 48 ...........................................................................................................

1

42

607932

CENTER SHAFT ................................................................................................

1

43

27123G01

CLUTCH PIN ......................................................................................................

1

44

607933

GEAR, 57 ...........................................................................................................

1

45

628152

DIFFERENTIAL ASSY (INCLUDES ITEMS 46, 53 & 55)...................................

1

46

628159

DIFFERENTIAL CASE COMPLETE (INCLUDES ITEMS 47 - 52) .............

1

47

628149

DIFFERENTIAL GEAR SET (INCLUDES ITEMS 48 & 49) ..................

1

48

*

DIFFERENTIAL SIDE GEAR .........................................................

2

49

*

DIFFERENTIAL PINION ................................................................

2

34

50

28723G01

DIFFERENTIAL SHAFT .......................................................................

1

51

28697G01

PIN, 4 x 40L..........................................................................................

1

52

26806G01

BALL BEARING (6007) ........................................................................

2

53

628155

GEAR, 60 COMPLETE (INCLUDES ITEM 52). ..........................................

1

55

26808G01

HEX HEAD BOLT, M10 x 1.25 x 26 MM LG................................................

6

56

607945

AXLE SHAFT L COMPLETE (INCLUDES ITEM 60)..........................................

1

607946

AXLE SHAFT R COMPLETE (INCLUDES ITEM 60) .........................................

1

BALL BEARING (6205DD)..........................................................................

2

AXLE CASE L COMPLETE ................................................................................

1

54

57 58 59 60

26811G01

61

607969

Page D-4

Fuji Transaxle Shop Rebuild and Service Parts Manual

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

62

607970

AXLE CASE R COMPLETE................................................................................

1

63

26814G01

SNAP RING, 52 MM............................................................................................

2

64

72260G01

FLANGED BOLT, M10 x 1.5 x 23 MM LG ...........................................................

10

65

607937

SHIFT SHAFT COMPLETE ................................................................................

1

66

26817G01

DOWEL TUBE ....................................................................................................

2

67

607936

GASKET (CASE) ................................................................................................

1

68

607935

HANGER.............................................................................................................

1

69

26823G01

FLANGED BOLT, M8 x 1.25 x 100 MM LG .........................................................

10

70

28724G01

FLANGED NUT, M8 x 1.25 ................................................................................

10

606403

SLOTTED NUT, M22 X 1.5 ................................................................................

2

71 72 73

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-5

FUJI TRANSAXLE

63

DETAIL A

9

60

5

10

11

7

24

56

9

28

8

3

4

29

27 37

6

38

64

30

39 40

61

31

41 42

69

43

16

65 15

14

44 36 37

66 19

13 12 DETAIL A

32

1

53

33 35 48

52

32 50

64

68

23

55 62

67

70

52

17 49 51

12

46 20

1 CASE L COMPLETE, AXLE ASSY includes items 3 - 12, 24 17 CASE R COMPLETE, AXLE ASSY includes items 12, 19 - 23

21

45 DIFFERENTIAL ASSY includes items 46, 53 & 55

22

26

46 DIFFERENTIAL CASE ASSY includes items 47 - 52 47 DIFFERENTIAL GEAR SET includes items 48 & 49 53 GEAR 60 COMPLETE ASSY includes item 52 56 AXLE SHAFT L COMPLETE ASSY includes item 60

58 60 63

58 AXLE SHAFT R COMPLETE ASSY includes item 60

Page D-6

Fuji Transaxle Shop Rebuild and Service Parts Manual

73

63 25

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

MODEL 627891 - ED58BA02 GAS REAR AXLE 1

628561

CASE L COMPLETE , AXLE (INCLUDES ITEMS 3 - 12, 24).............................

1

3

628148

GOVERNOR GEAR, COMPLETE...............................................................

1

4

628150

GOVERNOR SLEEVE.................................................................................

1

5

607904

FLAT WASHER ...........................................................................................

2

6

607905

THRUST BEARING.....................................................................................

1

7

607907

GOVERNOR GEAR SHAFT........................................................................

1

8

607910

GOVERNOR SHAFT...................................................................................

1

9

607909

FLAT WASHER, 6 MM ................................................................................

2

10

607911

OIL SEAL, 6 x 10 x 2.5 MM .........................................................................

1

11

607913

RETAINING RING E5 ..................................................................................

1

12

72259G01

OIL SEAL, 28 x 47 x 9 MM ..........................................................................

3

13

26818G01

STEEL BALL .......................................................................................................

1

14

26819G01

SPRING ..............................................................................................................

1

15

26831G01

GASKET, 10 ........................................................................................................

1

16

26820G01

FLANGED BOLT, M10 x 1.25 x 12 MM LG .........................................................

1

17

607942

CASE R COMPLETE, AXLE (INCLUDES ITEMS 12, 19 - 23) ...........................

1

19

607914

SELECT SHAFT, COMPLETE ....................................................................

1

20

607915

OIL SEAL, 13 x 22 x 5 .................................................................................

1

21

607916

SNAP RING, 13 MM ....................................................................................

1

22

607917

SPACER, 13 x 1 ..........................................................................................

1

23

607918

SPRING PIN................................................................................................

1

24

607919

AIR BREATHER ..........................................................................................

1

25

26770G01

OIL DRAIN PLUG ...............................................................................................

2

26

26771G01

GASKET, 14 ........................................................................................................

2

27

26785G01

BALL BEARING (6204).......................................................................................

1

28

607921

GOVERNOR GEAR, 34 ......................................................................................

1

29

607920

PIN, 6 x 12L ........................................................................................................

1

30

628151

INPUT SHAFT.....................................................................................................

1

2

18

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-7

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

31

607922

BALL BEARING (62/28) .....................................................................................

1

32

607923

BALL BEARING (TMB202).................................................................................

2

33

628153

COUNTER SHAFT .............................................................................................

1

35

628154

GEAR, 33 ...........................................................................................................

1

36

26786G01

SPACER, 20 x 2.2 MM .......................................................................................

1

37

26796G01

BALL BEARING (6304) ......................................................................................

2

38

72261G01

COLLAR, 20 x 8 MM ..........................................................................................

1

39

628156

GEAR, 18 ...........................................................................................................

1

40

26792G01

COLLAR, 24 x 12 MM ........................................................................................

1

41

628158

GEAR, 48 ...........................................................................................................

1

42

607932

CENTER SHAFT ................................................................................................

1

43

27123G01

CLUTCH PIN ......................................................................................................

1

44

607933

GEAR, 57 ...........................................................................................................

1

45

628152

DIFFERENTIAL ASSY (INCLUDES ITEMS 46, 53 & 55)...................................

1

46

628159

DIFFERENTIAL CASE COMPLETE (INCLUDES ITEMS 47 - 52) .............

1

47

628149

DIFFERENTIAL GEAR SET (INCLUDES ITEMS 48 & 49) ..................

1

48

*

DIFFERENTIAL SIDE GEAR .........................................................

2

49

*

DIFFERENTIAL PINION ................................................................

2

34

50

28723G01

DIFFERENTIAL SHAFT .......................................................................

1

51

28697G01

PIN, 4 x 40L..........................................................................................

1

52

26806G01

BALL BEARING (6007) ........................................................................

2

53

628155

GEAR, 60 COMPLETE (INCLUDES ITEM 52). ..........................................

1

55

26808G01

HEX HEAD BOLT, M10 x 1.25 x 26 MM LG................................................

6

56

607945

AXLE SHAFT L COMPLETE (INCLUDES ITEM 60)..........................................

1

607946

AXLE SHAFT R COMPLETE (INCLUDES ITEM 60) .........................................

1

BALL BEARING (6205DD)..........................................................................

2

AXLE CASE L COMPLETE ................................................................................

1

54

57 58 59 60

26811G01

61

607939

Page D-8

Fuji Transaxle Shop Rebuild and Service Parts Manual

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

62

607940

AXLE CASE R COMPLETE................................................................................

1

63

26814G01

SNAP RING, 52 MM............................................................................................

2

64

72260G01

FLANGED BOLT, M10 x 1.5 x 23 MM LG ...........................................................

10

65

607937

SHIFT SHAFT COMPLETE ................................................................................

1

66

26817G01

DOWEL TUBE ....................................................................................................

2

67

607936

GASKET (CASE) ................................................................................................

1

68

607935

HANGER.............................................................................................................

1

69

26823G01

FLANGED BOLT, M8 x 1.25 x 100 MM LG .........................................................

10

70

28724G01

FLANGED NUT, M8 x 1.25 .................................................................................

10

606403

SLOTTED NUT, M22 X 1.5 .................................................................................

2

71 72 73

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-9

FUJI TRANSAXLE

56

64

DETAIL A

9

53

5

10

11

7

24

49

9

28

38

3

4

30

57

39 40

54

31

41 42

62

43

16

58 15

8

29

27 37

6

14

44 45 37

59 19

13 12 DETAIL A

32 34

59

33

35 36

32 50

57

61

23

47 55

60

63

47 a

48

12

46 20

21

22

26

1 CASE L COMPLETE, AXLE ASSY includes items 3 - 12, 24 66

17 CASE R COMPLETE, AXLE ASSY includes items 12, 19 - 23 46 DIFFERENTIAL CASE ASSY includes items 47 - 48 49 AXLE SHAFT L COMPLETE ASSY includes item 53 51 AXLE SHAFT R COMPLETE ASSY includes item 53

Page D-10

65

51 53 56

Fuji Transaxle Shop Rebuild and Service Parts Manual

64

12 25

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

MODEL 617488 - FUJI WITH LSD GAS REAR AXLE 1

607941

CASE L COMPLETE, AXLE (INCLUDES ITEMS 3 - 12, 24)..............................

1

3

607901

GOVERNOR GEAR, COMPLETE ................................................................

1

4

628150

GOVERNOR SLEEVE ..................................................................................

1

5

607904

FLAT WASHER .............................................................................................

2

6

607905

THRUST BEARING.......................................................................................

1

7

607907

GOVERNOR GEAR SHAFT .........................................................................

1

8

607910

GOVERNOR SHAFT.....................................................................................

1

9

607909

FLAT WASHER, 6 MM ..................................................................................

2

10

607911

OIL SEAL, 6 X 10 X 2.5 MM..........................................................................

1

11

607913

RETAINING RING .........................................................................................

1

12

72259G01

OIL SEAL, 28 X 47 X 9 MM...........................................................................

3

13

26818G01

STEEL BALL .......................................................................................................

1

14

26819G01

SPRING ..............................................................................................................

1

15

26831G01

GASKET, 10 ........................................................................................................

1

16

26820G01

FLANGED BOLT, M10 X 1.25 X 12 MM LG ........................................................

1

17

630833

CASE R COMPLETE AXLE (INCLUDES ITEMS 12, 19 - 23) ............................

1

19

607914

SELECT SHAFT, COMPLETE ......................................................................

1

20

607915

OIL SEAL, 13 X 22 X 5 MM...........................................................................

1

21

607916

SNAP RING, 13 MM ......................................................................................

1

22

607917

SPACER, 13 X 1 ...........................................................................................

1

23

607918

SPRING PIN..................................................................................................

1

24

607919

AIR BREATHER ............................................................................................

1

25

26770G01

OIL DRAIN PLUG ...............................................................................................

1

26

26771G01

GASKET, 14 ........................................................................................................

1

27

26785G01

BALL BEARING (6204).......................................................................................

1

28

607921

GOVERNOR GEAR, 34 ......................................................................................

1

29

607920

PIN, 6 X 12L........................................................................................................

1

30

607947

INPUT SHAFT.....................................................................................................

1

2

18

Fuji Transaxle Shop Rebuild and Service Parts Manual

Page D-11

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY.

31

607922

BALL BEARING (62/28) .....................................................................................

1

32

607923

BALL BEARING (TMB202).................................................................................

2

33

607926

COUNTER SHAFT .............................................................................................

1

34

607927

GEAR, 36 ...........................................................................................................

1

35

607928

GEAR, 33 ...........................................................................................................

1

36

607929

SNAP RING, 19 MM ...........................................................................................

1

37

26796G01

BALL BEARING (6304) ......................................................................................

2

38

72261G01

COLLAR, 20 X 8 MM ..........................................................................................

1

39

26793G01

GEAR, 16 ...........................................................................................................

1

40

26792G01

COLLAR, 24 X 12 MM ........................................................................................

1

41

607931

GEAR, 45 ...........................................................................................................

1

42

607932

CENTER SHAFT ................................................................................................

1

43

27123G01

PIN CLUTCH ......................................................................................................

1

44

607933

GEAR, 57 ...........................................................................................................

1

45

26786G01

SPACER, 20 X 2.2 MM.......................................................................................

1

46

617486

LSD ASSEMBLY (INCLUDES ITEMS 47 - 48)...................................................

1

47

26806G01

BALL BEARING (6007).................................................................................

2

48

26808G01

HEX HEAD BOLT, M10 X 1.25 X 26 MM LG ................................................

6

49

607945

AXLE SHAFT L COMPLETE (INCLUDES ITEM 53)..........................................

1

607946

AXLE SHAFT R COMPLETE (INCLUDES ITEM 53) .........................................

1

BALL BEARING (6205DD) ...........................................................................

2

50 51 52 53

26811G01

54

607939

AXLE CASE L COMPLETE ................................................................................

1

55

607940

AXLE CASE R COMPLETE ...............................................................................

1

56

26814G01

SNAP RING, 52 MM ...........................................................................................

2

57

72260G01

FLANGED BOLT, M10 X 1.5 X 23 MM LG .........................................................

10

58

607937

SHIFT SHAFT COMPLETE................................................................................

1

59

26817G01

KNOCK PIPE......................................................................................................

2

60

607936

GASKET (CASE) ................................................................................................

1

61

607935

HANGER ............................................................................................................

1

Page D-12

Fuji Transaxle Shop Rebuild and Service Parts Manual

FUJI TRANSAXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

62

26823G01

FLANGED BOLT, M8 X 1.25 X 100 MM LG ........................................................

10

63

28724G01

FLANGED NUT, M8 X 1.25.................................................................................

10

64

606403

SLOTTED NUT, M22 X 1.5 .................................................................................

2

65

630835

OIL DRAIN PLUG W/ MAGNET..........................................................................

1

66

630836

GASKET, 18 ........................................................................................................

1

Fuji Transaxle Shop Rebuild and Service Parts Manual

QTY.

Page D-13

FUJI TRANSAXLE

Notes:

Page D-14

Fuji Transaxle Shop Rebuild and Service Parts Manual

E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA

Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department