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Unread 03-13-2019, 09:01 PM   #11
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Default Re: 2004 DCS drive train issue

back to battery voltage guestion. What is voltage under load, and 10 hours after being fully charged but not used.
To be sure you did remove and check both brake drums correct?
Your description of motor turning is confusing as if motor spinning the same wether under load(up a hill) as when on flat ground.
Or motor turning but cart just slows down.
voltage when charged then when under load helps forum diagnos problem😊
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Unread 03-13-2019, 09:22 PM   #12
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Default Re: 2004 DCS drive train issue

Quote:
Originally Posted by Cobra,1 View Post
back to battery voltage guestion. What is voltage under load, and 10 hours after being fully charged but not used.
To be sure you did remove and check both brake drums correct?
Your description of motor turning is confusing as if motor spinning the same wether under load(up a hill) as when on flat ground.
Or motor turning but cart just slows down.
voltage when charged then when under load helps forum diagnos problem😊
Ok, charged it this morning, and just checked the volts. 38 volts, then goes down to around 34 when you hit the gas (cart is on jack stands with wheels removed). Is this the right method?
Both drums removed.
Motor turns but the cart does not move. On the last ride, it just slowly lost drive-until it came to a stop. When you push the gas, you can hear the motor working, but it will not move.
Hope this helps-and thanks!
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Unread 03-13-2019, 10:47 PM   #13
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Default Re: 2004 DCS drive train issue

Quote:
Originally Posted by nealer View Post
Ok, charged it this morning, and just checked the volts. 38 volts, then goes down to around 34 when you hit the gas (cart is on jack stands with wheels removed). Is this the right method?
Both drums removed.
Motor turns but the cart does not move. On the last ride, it just slowly lost drive-until it came to a stop. When you push the gas, you can hear the motor working, but it will not move.
Hope this helps-and thanks!
34 is low, especially with no load on the cart. Time to check each battery individually. You can refer to the attached chart curtesy of johnnieb. Get readings to the second decimal. Ie: 6.xx if necessary, do the test while going up a good hill. You’ve probably got a bad battery.
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Unread 03-14-2019, 10:27 AM   #14
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Default Re: 2004 DCS drive train issue

Two things, be extra careful when hitting the gas pedal and the cart is in the air. If your battery pack was good and you mash the pedal to the floor you could over-rev your motor.

and 34v with no load on the cart sounds like batteries are toast. But... You said the motor is running and the wheels are not spinning, how do you know the motor is running? If the motor is not spinning and the wheels are not spinning it sounds like a shot battery pack.

If the motor is indeed spinning and the wheels are not turning it sounds like a stripped gear in the diff and a shot battery pack...

Have you pulled the motor to see if the intermediate gear (or whatever it's called) is stripped or?
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Unread 03-14-2019, 12:52 PM   #15
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Default Re: 2004 PDS drive train issue

The motor is direct coupled, so if the motor is turn and the tires aren't, something is stripped or broken.

There are spline couplings between motor and differential, between differential and axles and between axles and brake drums. Any of the five sets of spline couplers could be stripped or either of the two axle shafts could be broken. In addition any of the gears in the differential could be stripped.

Attached is the service manual for the rear axle assembly and you can download the Owner. parts and service manuals for your cat here: Basic Ezgo electric golf cart wiring and manuals.
They are the top three PDF files.
Attached Files
File Type: pdf DANA AXLE, 1988-95, 28148G01.pdf (3.93 MB, 0 views)
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Unread 03-14-2019, 05:44 PM   #16
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Default Re: 2004 PDS drive train issue

I hope it is not the batteries, just bought them 4 months ago!

Here what i got on the batteries:
6.23, 6.27, 6.30, 6.32, 6.33. 6.32

I can hear the motor turning, and it doesn't sound good! Kinda a dull roar, coming from the motor/differential.
I guess i will pull the motor and check it out...

Thanks again for all the help guys!
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Unread 03-14-2019, 06:12 PM   #17
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Default Re: 2004 PDS drive train issue

Don't try to spin it up when it's not connected to the rear end. Motor only has one of the two bearings.
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Unread 03-19-2019, 07:21 PM   #18
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Default Re: 2004 PDS drive train issue

Pull the motor and inspect the input shaft and bearing. You'll need:

7/16 socket and wrench
1/2 socket or wrench
Snap ring pliers
A small flathead screwdriver (seal removal
T25 torx

Use caution as the motor is heavy. I've found that taking off the driver side tire makes things easy as well.

Considering the noise you have going on it wouldn't be a bad idea to pull the axle as well. It's held in with a snap ring and requires light force to remove from the housing. Hope this helps

Sent from my SM-G935V using Tapatalk
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Unread 03-19-2019, 08:33 PM   #19
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Default Re: 2004 PDS drive train issue

Quote:
Originally Posted by jdglen93 View Post
Pull the motor and inspect the input shaft and bearing. You'll need:

7/16 socket and wrench
1/2 socket or wrench
Snap ring pliers
A small flathead screwdriver (seal removal
T25 torx

Use caution as the motor is heavy. I've found that taking off the driver side tire makes things easy as well.

Considering the noise you have going on it wouldn't be a bad idea to pull the axle as well. It's held in with a snap ring and requires light force to remove from the housing. Hope this helps

Sent from my SM-G935V using Tapatalk
Yes, it does help, thank you. looks pretty straight-forward!
I guess i know what i will be doing this weekend.
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Unread 03-20-2019, 06:10 AM   #20
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Default Re: 2004 PDS drive train issue

Quote:
Originally Posted by nealer View Post
I hope it is not the batteries, just bought them 4 months ago!

Here what i got on the batteries:
6.23, 6.27, 6.30, 6.32, 6.33. 6.32

I can hear the motor turning, and it doesn't sound good! Kinda a dull roar, coming from the motor/differential.
I guess i will pull the motor and check it out...

Thanks again for all the help guys!
This makes me think that the motor is getting power, but not actually spinning... Anyone else think this is the issue?
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