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Unread 01-29-2014, 09:09 PM   #1
Gone Wild
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Default 92 gearbox is leaking help!!!

Help?? I went on a service call today. Customer has a 92 club car ds. He said something is leaking.

As I looked under the gearbox, I can see where fluid has leaked, and mixed with grass and dirt etc. Upon closer examination, I can see the bolt that is on the very bottom, has been tampered with?

Someone had previously pulled a fast one on the customer and tried to ciover it up with blue colored silicone or atf??

I am attaching some pictures here. It kinda looks like maybe someone either stripped out a bolt or even possibly broke off a piece of the casing?

The bolt he has in the hole, has a nut run all the way up the bolt, before the bolt goes into the hole.

Tomorrow I plan to try and unscrew the bolt and see what I can find. I hope the customer doesn't need to replace the entire gear box housing.
Any advice, input, or suggestions?

thanks
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Unread 01-29-2014, 09:47 PM   #2
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Default Re: 92 gearbox is leaking help!!!

They probably broke off the original bolt down in the hole, so they had to put a nut on the new bolt to act as a spacer because it wouldn't go in all the way with the broken off piece down in there...

I would try to get that broken off piece out of there...
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Unread 01-29-2014, 10:04 PM   #3
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Default Re: 92 gearbox is leaking help!!!

HTF will I get it out?

Do you think there is anyway I can get this thing to stop leaking?
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Unread 01-29-2014, 10:09 PM   #4
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Default Re: 92 gearbox is leaking help!!!

It looks like it is leaking all over and not just at the bottom. I bet someone opened it up once and did not properly reseal it...

You may be able to drill into the broken off piece and then figure out something you can try to stick in there and pull it out. Maybe you could try to epoxy a nail to the piece then once it is attached twist it out?
Just thinking out loud...
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Unread 01-29-2014, 10:15 PM   #5
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Default Re: 92 gearbox is leaking help!!!

They make extractors if you can get to the broken bolt. I have some that dig in pretty good with a reverse drill. Having a hammer drill helps also.
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Unread 01-29-2014, 10:41 PM   #6
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Default Re: 92 gearbox is leaking help!!!

Wow, just thinking about trying to fix this gives me a headache!

In order to take this apart and seal it correctly, what all is involved? Looks like the motor has to come off, does the entire rear end have to be removed and taken apart?
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Unread 01-30-2014, 06:53 AM   #7
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Default Re: 92 gearbox is leaking help!!!

if the case seem is leaking that bad you will have to split it and reseal it. it is so dirty its hard to pinpoint the leak. i would clean it, check fluid and explain to the customer that a recheck in a week after some use to see where the leak actual starts may save them money. if someone broke that bolt in the case drill a small whole in the broken peice and use an ez-out extractor to remove it.
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Unread 01-30-2014, 10:02 AM   #8
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Default Re: 92 gearbox is leaking help!!!

I will try cleaning it up some today. I will be gone next week ( heading to augusta to club car to take a 3 day training class), so I will tell the customer to drive it while I am gone.

I hope the case is not broke or damaged. I don't know if you can still get them, and if you can, I don't think this old cart is worth it.

Thanks for the advice everyone. I will try cleaning it up today. Keep the advice coming please, I haven't had to get into any club car rear end work yet.
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