Textron EZGO 610987 User manual

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DANA ELECTRIC TRANSAXLE
STARTING MODEL YEAR: 2008
SHOP REBUILD AND
SERVICE PARTS MANUAL
610987

Page i
Dana Electric Transaxle Shop Rebuild and Parts Manual
SHOP REBUILD AND
PARTS MANUAL
DANA ELECTRIC TRANSAXLE
E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information
contained in this manual is subject to change without notice.
E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone], FAX: [phone]
OUTSIDE USA PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GA 30906-3852 U.S.A.

Page ii
NOTES
Dana Electric Transaxle Shop Rebuild and Parts Manual
Notes:

INTRODUCTION
Page iii
Dana Electric Transaxle Shop Rebuild and Parts Manual
Read all of each section before attempting any procedure. Pay particular attention to all Warnings, Cautions, and Notes.
HOW TO USE THIS MANUAL
This manual is designed to suit the needs of mechanics
at all levels of experience with the E-Z-GO electric
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 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:
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.
We strongly recommend that no matter what your experi-
ence level, you use this manual as a guide when disas-
sembling, repairing/overhauling, and reassembling the
transaxle. Before working on the transaxle, read and
understand the text and in particular each WARNING,
CAUTION, and NOTE.
Some illustrations may show components that differ from
your transaxle. This is the result of ongoing improve-
ments to the transaxle design.
WARNINGS, CAUTIONS, AND NOTES
Throughout this manual, the following WARNINGS,
CAUTIONS, and NOTES are used. For the protection of
all personnel and the vehicle, be aware of and observe
the following:
A WARNING indicates a hazardous condi-
tion which could result in serious injury or
death.
A CAUTION indicates a condition that may result in
damage to the vehicle or surrounding facilities.
A NOTE 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 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-
nent should move unexpectedly.
Some components are heavy, spring-loaded, highly-cor-
rosive, 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.

INTRODUCTION
Page iv
Dana Electric Transaxle Shop Rebuild and Parts Manual
Read all of each section before attempting any procedure. Pay particular attention to all Warnings, Cautions, and Notes.
Before working on vehicle, remove all jewel-
ry (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.
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 pro-
tection 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 partic-
ular attention to the polarity of the battery
terminals. Never confuse the positive and
negative cables.
Battery posts, terminals and related acces-
sories 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.
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.
Never work around or operate a vehicle in
an environment 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 hydrocarbon fuels. Carbon
monoxide is a dangerous gas that can
cause unconsciousness and is potentially
lethal.
The following are symptoms of carbon mon-
oxide 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 Sec-
tion in your Repair and Service Manual).
Aerosol containers of battery terminal pro-
tectant 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.

Dana Electric Transaxle Shop Rebuild and Parts Manual
TABLE OF CONTENTS
TITLE PAGE
Transaxle Disassembly
Differential cover Plate Removal ................................................................................................................... A-1
Axle Shaft Assembly Removal...................................................................................................................... A-3
Input Gear Assembly Removal ...................................................................................................................... A-4
Differential-Carrier Assembly Removal ......................................................................................................... A-5
Intermediate Gear Assembly Removal ......................................................................................................... A-6
Inspection of Parts
Oil Seal Inspection......................................................................................................................................... B-1
Bearing Inspection......................................................................................................................................... B-1
Cover Plate Inspection................................................................................................................................... B-1
Gear Teeth Inspection ................................................................................................................................... B-1
Transaxle Reassembly
Intermediate Gear Assembly Installation ....................................................................................................... C-2
Differential-Carrier Assembly Installation....................................................................................................... C-3
Input Gear Assembly Installation ................................................................................................................... C-4
Axle Shaft Installation .................................................................................................................................... C-5
Differential Cover Plate Installation................................................................................................................ C-6
Illustrated Parts Breakdown

Dana Electric Transaxle Shop Rebuild and Parts Manual
TABLE OF CONTENTS
Notes:

A
TRANSAXLE DISASSEMBLY
Page A-1
Dana Electric Transaxle Shop Rebuild and Parts Manual
TRANSAXLE DISASSEMBLY
Tool List Qty. Required
Extension, 4", 3/8" drive ............................................. 1
Small diameter pick-up 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
Socket, 12mm, 3/8" drive ............................................ 1
Socket, 14mm, 3/8" drive ............................................ 1
Socket, 17mm, 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
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, discol-
ored, or that rotate roughly or noisily.
Keep work area clean and well organized
while performing the operations described
in this manual. This will help prevent acci-
dents and reduce the possibility of mistakes
that could damage or impair the perfor-
mance of the transaxle.
Because some mating parts with wear surfaces were
machined together when the transaxle was manufac-
tured, or 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 expec-
tancy of the transaxle. Mark and sort all parts as they
are disassembled so that they will be reassembled
and installed in their original positions.
Differential Cover Plate Removal
1. Remove rubber plug. Take care not to damage the
plug flange. (Ref Fig. A-1 on page A-1) (Ref Fig.
A-2 on page A-1)
Fig. A-1 Rubber Plug Removal, Step 1
Fig. A-2 Rubber Plug Removal, Step 2

TRANSAXLE DISASSEMBLY
Page A-2 Dana Electric Transaxle Shop Rebuild and Parts Manual
2. Remove ten bolts from differential cover plate.
(Ref Fig. A-3 on page A-2) (Ref Fig. A-4 on page
A-2)
Fig. A-3 Differential Cover Plate, Assembled
Fig. A-4 Removing Bolts from Differential Cover
Plate
3. Carefully insert a rigid gasket scraper between the
cover plate and the differential housing. Pry gently
and remove differential cover plate. Use caution
when prying to avoid bending cover plate. (Ref
Fig. A-5 on page A-2) (Ref Fig. A-6 on page A-2)
Fig. A-5 Removing Differential Cover Plate
Fig. A-6 Bolts and Differential Cover Plate Removed

TRANSAXLE DISASSEMBLY
Page A-3
Dana Electric Transaxle Shop Rebuild and Parts Manual
Axle Shaft Assembly Removal
1. Remove outside axle nut, spacer, and hub from
driver-side axle tube, using a 15/16" socket.
Repeat on passenger-side axle tube. (Ref Fig. A-7
on page A-3) (Ref Fig. A-8 on page A-3)
Fig. A-7 Assembled End of Axle Tube
Fig. A-8 Hardware and Hub Removed from End of
Axle Tube
2. Remove outer snap ring and axle shaft from
driver-side axle tube. The bearing, inner snap ring,
and oil seal remain assembled to axle shaft.
Repeat on passenger-side axle tube. (Ref Fig. A-9
on page A-3) (Ref Fig. A-10 on page A-3)
Fig. A-9 Axle Shaft, Outer Snap Ring, and Bearing
Shown Assembled in Axle Tube
Fig. A-10 Removing Axle Shaft From Axle Tube
3. Remove bearing, inner snap ring, and oil seal from
driver-side axle shaft. Repeat on passenger-side
axle shaft.

TRANSAXLE DISASSEMBLY
Page A-4 Dana Electric Transaxle Shop Rebuild and Parts Manual
Input Gear Assembly Removal
1. At axle housing, using a seal puller, remove oil
seal from Input Gear Assembly. Discard oil seal.
(Ref Fig. A-11 on page A-4)
Fig. A-11 Removing Oil Seal from Input Gear
Assembly
2. At axle housing, remove retaining ring from input
gear assembly. (Ref Fig. A-12 on page A-4)
Fig. A-12 Removing Retaining Ring from Input Gear
Assembly
3. At axle housing, remove input gear assembly. The
input shaft bearing and housing should be a slip-
fit. Use channel-lock or standard pliers for gripping
and removing. Discard O-ring found in the differ-
ential housing groove. (Ref Fig. A-14 on page A-
4). Two bearings remain assembled to input gear
assembly. (Ref Fig. A-13 on page A-4) (Ref Fig. A-
14 on page A-4)
Fig. A-13 Oil Seal, Retaining Ring, and Input Gear
(With Two Bearings Attached) Removed
4. Remove O-ring from axle housing. Discard O-ring.
Fig. A-14 Axle Housing with Input Gear Assembly
and Hardware Removed

TRANSAXLE DISASSEMBLY
Page A-5
Dana Electric Transaxle Shop Rebuild and Parts Manual
Differential-Carrier Assembly Removal
1. From axle housing, remove four saddle bolts from
saddles, then remove saddles. (Ref Fig. A-15 on
page A-5)
Note the alignment marks on both the housing and saddles.
Saddles must be reassembled on the same side from which
removed. If alignment marks are missing, use a permanent
marker to mark saddle and housing.
Fig. A-15 Removing Saddle Bolts from Saddles
2. Remove differential-carrier assembly from axle
housing. (Ref Fig. A-16 on page A-5)
Fig. A-16 Removing Differential-Carrier Assembly
from Axle Housing
Fig. A-17 Saddle Bolts, Saddles, and
Differential-Carrier Assembly Removed
3. Remove drive gear (2) from differential-carrier (3)
by removing four locknuts and four hex head bolts
(1).
Do not remove bearings from differential-carrier.
The differential-carrier is replaced as a single unit. No disas-
sembly of the clutch is required.
If working on a hard surface, handle the ring gear
carefully to prevent damage to the ring gear teeth.

TRANSAXLE DISASSEMBLY
Page A-6 Dana Electric Transaxle Shop Rebuild and Parts Manual
Intermediate Gear Assembly Removal
1. Remove two end cap plugs from axle housing.
(Ref Fig. A-18 on page A-6)
Fig. A-18 End Cap Plug
To remove end cap plug, drill a small hole in the
plug, insert a screw into the drilled hole, and pull the
plug out using pliers. Do not pry the plug out of the
axle housing. Prying the end plug out of the axle
housing may cause damage to the housing.
2. Using snap-ring pliers, remove two retaining rings
from axle housing. (Ref Fig. A-19 on page A-6)
Fig. A-19 Removing Retaining Rings
3. Push intermediate gear assembly (1) toward wide
opening of axle housing (2) and remove bearing
(3) from intermediate gear assembly shaft (4).
4. Push intermediate gear assembly (1) to narrow
side of gear housing and remove bearing (5) from
intermediate gear assembly shaft (4).
5. Remove intermediate gear assembly by tilting
upward (on wide side) and lifting outward to clear
slot. (Ref Fig. A-20 on page A-6)
Fig. A-20 Intermediate Gear Assembly
6. Remove intermediate gear assembly from axle
housing.
7. If damaged, remove two O-rings from intermediate
gear assembly shaft. Discard O-rings.
8. Remove two O-rings from axle housing. Discard
O-rings. (Ref Fig. A-21 on page A-6)
Fig. A-21 O-Rings Removed from Axle Housing

B
INSPECTION OF PARTS
Page B-1
Dana Electric Transaxle Shop Rebuild and Parts Manual
INSPECTION OF PARTS
We strongly recommend that all parts found to be damaged be
replaced.
All parts must be thoroughly cleaned, and free of all
dirt, oil, grease, or residue of any kind before begin-
ning this section. It is especially important that your
work area be clean and well-organized while per-
forming the operations described in this section.
Oil Seal Inspection
It is recommended that any oil seals that are removed, (and all
seals, if a transaxle is more than one year old when disassem-
bled), be replaced with new ones.
1. Perform visual inspection of all oil seals for dam-
age of any kind. Replace as necessary.
Bearing Inspection
Remove press-fit bearings only if they are damaged, exces-
sively 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 dam-
age and excessive wear. Replace bearings that
are pitted, nicked, burred, discolored, or that rotate
roughly or noisily.
Cover Plate Inspection
1. Perform visual inspection of inside of differential
cover plate for contact with gear teeth. Replace as
necessary.
Gear Teeth Inspection
1. Perform visual inspection of gears for unusual
wear patterns, and chipped, broken, or missing
teeth. Replace as necessary.

INSPECTION OF PARTS
Page B-2 Dana Electric Transaxle Shop Rebuild and Parts Manual
Notes:

C
TRANSAXLE REASSEMBLY
Page C-1
Dana Electric Transaxle Shop Rebuild and Parts Manual
TRANSAXLE REASSEMBLY
Tool List Qty. Required
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
Non-ferrous punch, medium........................................ 1
Non-ferrous punch, small ............................................ 1
Ratchet, 3/8" drive....................................................... 1
Ratchet, 1/2” drive....................................................... 1
Flat Blade screwdriver, medium .................................. 1
Phillips screwdriver, #2................................................ 1
Socket, 12mm, 3/8" drive ............................................ 1
Socket, 14mm, 3/8" drive ............................................ 1
Socket, 17mm, 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
Prior to transaxle reassembly, all parts must be thor-
oughly cleaned and free of dirt, oil, grease, or resi-
due of any kind, free of nicks, burrs, or 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 manufac-
tured, or 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.
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, and then to specified torque on the sec-
ond pass.
Fasteners that are plated, or are lubricated when installed, are
considered ‘‘wet“ and require approximately 80% of the speci-
fied torque for ‘‘dry” fasteners. All transaxle fasteners are con-
sidered ‘‘wet”.
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.

TRANSAXLE REASSEMBLY
Page C-2 Dana Electric Transaxle Shop Rebuild and Parts Manual
Intermediate Gear Assembly Installation
1. Lubricate two O-rings with 30W motor oil and
install them into axle housing. (Ref Fig. A-1 on
page C-2)
Fig. A-1 Intermediate Gear Assembly O-Rings
Installed
2. If damaged or removed, install two new O-rings on
intermediate gear assembly shaft.
3. Tilt intermediate gear assembly (1) upward on
wide opening of axle housing (2), lower over slot,
and slip into gear housing.
Fig. A-2 Intermediate Gear Assembly Components
4. Push intermediate gear assembly (1) toward nar-
row side of gear housing and install bearing (3) on
intermediate gear assembly shaft (4).
5. Push intermediate gear assembly (1) toward wide
opening of axle housing (2) and install bearing (5)
on intermediate gear assembly shaft (4). (Ref Fig.
A-3 on page C-2)
Fig. A-3 Intermediate Gear Assembly Installed
6. Using snap-ring pliers, install two retaining rings
into axle housing. (Ref Fig. A-4 on page C-2)
Fig. A-4 Retaining Rings Installed

TRANSAXLE REASSEMBLY
Page C-3
Dana Electric Transaxle Shop Rebuild and Parts Manual
7. Install two new end cap plugs into axle housing.
(Ref Fig. A-5 on page C-3)
Fig. A-5 End Cap Installed
Differential-Carrier Assembly Installation
1. Install drive gear (2) on differential-carrier (3)
using four hex head bolts and four locknuts (1).
Tighten locknuts to 55 to 63 lb-ft (75 to 85 N•m).
Fig. A-6 Saddle Bolts, Saddles, and
Differential-Carrier Assembly Removed
2. Position differential-carrier into axle housing. (Ref
Fig. A-7 on page C-3)
Fig. A-7 Installing Differential-Carrier into
Axle Housing
For accurate torque readings, make sure threads are
clean and lightly lubricated.
Make sure the saddles are installed in their original positions
and orientation. Align the saddles with the alignment marks
prior to installation.
3. Install saddles into axle housing using four saddle
bolts. Tighten bolts to 35 to 45 lb-ft (46 to 61 N•m).
(Ref Fig. A-8 on page C-3)
Fig. A-8 Installing Saddle Bolts and Saddles

TRANSAXLE REASSEMBLY
Page C-4 Dana Electric Transaxle Shop Rebuild and Parts Manual
Input Gear Assembly Installation
1. Lubricate O-ring with 30W motor oil and install into
axle housing groove. (Ref Fig. A-9 on page C-4)
Fig. A-9 O-Ring Installed in Input Gear Assembly
2. Install input gear assembly (with bearings) into
axle housing by tilting assembly slightly upward at
an angle while pushing inward to clear the inter-
mediate gear.
Fig. A-10 Oil Seal, Retaining Ring, and Input Gear
(With Two Bearings Attached)
3. Install retaining ring into the axle housing groove.
(Ref Fig. A-11 on page C-4)
Fig. A-11 Installing Retaining Ring into Input Gear
Assembly and Axle Housing
4. Install oil seal over input gear assembly and into
axle housing. Seal must be installed evenly by
using a seal driver or similar tool. (Ref Fig. A-12 on
page C-4)
Fig. A-12 Installing Oil Seal into Input Gear
Assembly