Separating intermediate gearset

Cayman Jan

Hi guys! I am rebuilding a 2006 TXT.
I have encountered a problem: i need to separate the gears on the intermediate gear set, so I can replace one of them to the one supplied in the 1:6 kit.
Taking the diff apart went well once I bought the correct tools.

I see a kind of rolled up steel "thingy" pressed in in a hole between the shaft and gear, I assume this stops the gear from spinning on the shaft?
I have tried to use force to get the shaft / gear apart, but failed.
What am I supposed to do?
Grateful for any instructions!

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

93yellowclubcar

The rolled up steel thingy is probably a roll pin? If so you can drive it out with something of small diameter and a hammer. The old gears will have to be pressed off and the new back onto the shaft.

Cayman Jan

I tried to pry it out, but no luck. The hole where it is does not go all the way through, so I can not punch it out.

sportcoupe

The roll pin is installed after the gear is pressed on. It cannot be removed till you press the gear off. Most likely the new gear set doesn't have a groove for the roll pin and it isn't used.

Attached Images

image23.jpg (190.8 KB, 0 views)

Cayman Jan

Super! So basically I need to find a friendly mechanic with a press, and swap them. No need for a rollpin to be installed .
Is it enough to press on the new gear, or should he use some kind of glue? ( superglue or similar?
Or maybe ask him to put a couple of spot welds where the new gear and axle meet?
I am a novice when it comes to gear cases, as you can read!

cgtech

Just "press fit" will do fine, do not weld on your gears, its not needed and could be harmful to the gear. It is sometimes even difficult to get the gear off with the press, it isnt gonna slip.

Cayman Jan

Thanks for the info, it helps tremendously!

Cayman Jan

Ok, so I had my car workshop swap the gears on the intermediate shaft.
I then replaced the gear on the output shaft.
Tried to assemble, but then came a problem. The output shaft only fits if turned 180 degrees, so the output shaft gear engages the left gear on the intermediate! That is - the gear that also engages the input gear!!

I am truly puzzled! What have I done wrong?

sportcoupe

You probably mean input shaft. Double check you put the intermediate gear in the correct way. It will fit either way. Attached is the manual with pretty good photos. I also attached a not so great exploded picture of it all.

Attached Images

rear gears.jpg (97.3 KB, 0 views)

Attached Files

dana electric transaxle,2008,610987-A.pdf (2.15 MB, 0 views)

Cayman Jan

I did not remove or touch the input gear. I had the intermediate gear swapped to the one supplied.
Plus I swapped myself the output shaft gear, (simple with only 4 bolts).
I am confused, should the new small gear ( not the new one with the 4 bolt holes) go on the primary or on the intermediate?