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Unread 06-02-2016, 09:39 PM   #1
Not Yet Wild
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Location: Ocracoke island
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Default Rear end removal

Yet another stuck motor/armature thread, sorry.
2002 CC DS series.
I'm trying to remove the motor for service and the motor casing has released but not the armature. Can't get the casing off completely due to frame.
Am going to attempt to take the rear end off so I can try the reverse the brake drum, bang on the concrete method.
I want to confirm procedure.
Jack cart up
Disconnect brake lines at brake drums.
Remove shock fasteners.
Disconnect leaf springs and voila ?
When I remove the drum to reverse are there any concerns I should have ?
Thanks all.
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Unread 06-02-2016, 10:03 PM   #2
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Smile Re: Rear end removal

Removing the brake drum and reversing it has nothing to do with getting the motor out...the best way I found is to take the three bolts out that hold the motor to the rear end and then use some up and down motion to try to break it loose...if you can get it backed off even a little you can squirt penetrating oil in on the shaft a let it sit over-night and then push the motor back towards the rear end and then start moving it up and down again....if all else fails then pull the entire rear-end so you can get more leverage or pull the motor apart. In some posts guys have banged the motor and rear end on the floor to try to jar it apart.
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Unread 06-02-2016, 10:24 PM   #3
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Default Re: Rear end removal

I am trying to avoid removing the rear end if possible
Should I be concerned about the brushes pushing the motor back toward differential ?
I've sprayed the shaft with penetrating oil and ill see what happens tomorrow.
I'm being careful not to pry to hard on gear box casing
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Unread 06-02-2016, 10:32 PM   #4
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Default Re: Rear end removal

yes you are good to go

Quote:
Originally Posted by TahoeDawgZ71 View Post
Take the rear end out of the car. Take the passenger side tire off of the rear end. Take brake drum off. Flip brake drum around backwards and tighten lug nuts to where they are snug enough to hold the drum to the axle. Don't torque them down. With the aid of an assistant, lift the rear end up 3 - 4 feet into the air and drop the rear end onto a concrete floor onto the inverted brake drum. The drum is inverted so you don't damage the wheel studs during this process. The motor will fall off as soon as it hits the ground. If it doesn't, try it again. I've never had to drop one more than three times. Don't laugh. Try it and thank me later.
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Unread 06-03-2016, 08:16 AM   #5
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Default Re: Rear end removal

I think the idea behind reversing the drums was to lessen the damage potential from dropping the axle on its end.

I don't think mine was the norm but I slammed mine on end 100s of times over a 2-3 day period and never was able to get it to release. Ended up slamming it so hard that I broke the differential.

I did get it off later with a cutting torch just to win the battle.

Worse case, plumquick has or did have reasonably priced rear end complete. And the bandit ended up about the same even without the core being returned.
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Unread 06-03-2016, 11:49 AM   #6
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Smile Re: Rear end removal

But in all of those cases listed the rear end had to come out of the cart...
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Unread 06-03-2016, 01:15 PM   #7
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Default Re: Rear end removal

Weekend tomorrow. The rear end comes out !
Hopefully....
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Unread 06-04-2016, 07:03 PM   #8
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Default Re: Rear end removal

Who is this TahoeDawgZ71 ? I praise thee.
After trying everything else, of course, I removed rear end.
One time ! I dropped it one time and popped off like butter.
Chipped the brake drum a little but should be able to get another pretty quick.
The armature is separated from the case now and won't go back in because of the brushes, but all is well.
Thanks all
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Unread 06-04-2016, 07:12 PM   #9
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Default Re: Rear end removal

Quote:
Originally Posted by toddy View Post
... Who is this TahoeDawgZ71 ? I praise thee....
David Hicks at http://www.revolutiongolfcars.com/ is one of our site sponsors and known as member TahoeDawgZ71 who like many shop owners freely donate their time here helping us out!
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Unread 06-04-2016, 10:10 PM   #10
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Smile Re: Rear end removal

You will have to disassemble the motor now in order to get the brushes back in place...start by marking the case and end cover so that when you go to put it back together you will have everything lined up. This will give you a chance to check the brushes and while you have opened up replace the rear bearing in the motor. Ask if you need help...you will have fun with the rear bearing retainer but there are some tricks that will help.
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