TTF Limo-GT Manuel utilisateur
TTF Limo-GT
Service work instructions
1
Jacks and lifts: Vehicle Jack point locations:
!Special cases apply for Vendo and pre
2017 vehicles!
2
Workshop guidelines
Lifting:
2 Column lift
Jack
Scissor lift
Handbrake (mechanical,
cables)
Disc Brake (front)
Brake Pedal assembly (hydraulic)
(incl. Brake Fluid res. and Brake
Master Cylinder)
Brake system layout
Drum brake
(rear)
3
Contents:
●Rear suspension overview
●Rear axle and differential
○Overview
○Maintenance
○Replacement
Useful information and
recommendations:
●Use 800ml of oil in the
differential, recommended type
Tranself B 80W90.
●Always thoroughly clean the
differential and its components
before reassembly.
●Be sure to use correct spacer (there
are similar, but different versions
with different length and diameter)
●Check free wheel movement after
installing differential components
and/or motor
●Always re-torque wheel bolts after
100km.
Rear suspension
Things to look out for:
●Noise and vibrations coming
from the rear axle while driving.
●Metal residue and dirt on the
filler cap or in the differential oil.
●Oil leaks
Possible issues:
●Broken differential gears
●Broken drive axle
●Leaking differential seals
●Work or leaking bearings
●Worn suspension bushings
4
E
D
A
B
Rear suspension overview
A. Springs
B. Dampers
C. Arms
D. Swaybar
E. Rubber stop
F. Brackets and spacers
Springs and arms connected to the frame
Dampers connected with brackets and spacers spacers
Stabilizing rod also connected with brackets and spacers
5
●Known issues with the rear axle
○Noise when pushing tuk (low tone) indicative of a
broken differential
○Motor turning, but vehicle does not move
■Either differential or drive shafts are broken
○Contaminated oil will lead to differential failure
(make sure there are no loose metal parts in the oil)
○When replacing the differential, it is advised to also
replace the drive shafts. Old and new components
may not be mix&match
○Oil leaks can be caused by bad seals:
■Drive shaft seals
■Differential gasket
■Differential side seals
■Differential motor seal
Rear axle and differential: Maintenance 6
Differential removal and installation part 1
1. Disassemble drive shafts
a. Remove wheels and brake drums to reveal drive shaft.
b. Unbolt the 4 M8 bolts from the back of the drum brake
anchor plate.
c. Use an axle puller set to remove the axle
2. Remove the motor
a. Perform service power disconnect and disconnect the
main battery B- from the motor controller (see safety
instruction section)
b. Open the motor cable enclosure and disconnect all
cables and connectors. Remove the motor cable
enclosure.
c. Unbolt 6 M6 hex bolts from the motor.
d. Support the motor with a garage jack and slide it from
the drive axle (to the right).
e. Installation is the reverse procedure
f. Apply grease on the spline before installing the motor
g. Torque values:
i. Motor flange M6: 14Nm
ii. Motor cable terminal: 12Nm
Rear axle and differential maintenance 7
Differential removal and installation part 2
3. Remove the draining plug (underside differential bell housing)
and drain all differential oil, check the inside of the plug for
metal debris (there is a magnet here). Lots of debris indicates
excessive gear wear.
4. Unbolt all differential bolts and remove the differential. (Pre
2017 vehicles have axle structure that needs to be removed as
well. If this structure is welded in place it needs to be cut away
and reinstalled using a retrofit flange kit)
Installation:
1. Thoroughly clean the inside of the axle and all parts to remove
all debris and dirt.
2. Clean the contact surface of differential and axle and put
silicone gasket sealer paste on the flange and install the green
gasket.
3. Fit new differential, use lock bonding material on the bolts and
tighten the bolts with 14Nm. (TTF recommends to install new
drive shafts whenever installing a new differential)
4. Fill the differential with 80ml Tranself B 80W90.
5. Reassemble all other parts.
Rear axle and differential maintenance 8
●The Tuk Tuk has several body parts that can be
replaced in case of damage.
●Please check type of e-tuk before ordering spare
parts, older Tuk Tuks have different body parts
than the Limo GT.
Body replacement 9
Old Tuk Tuk has a small step-in and a
continuous body around the passenger
section
New Limo GT Tuk Tuk has a large step-in
and smaller body panels surrounding the
passengers
10
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