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Old 11-15-2011, 06:39 PM   #1
jonequest
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Default New input shaft is noisy as hell. What to do???

I recently replaced my motor and while taking it apart niticed that the old input shafdt had damaged splines and a leaking oil seal so I replaced it with an input shaft kit.

The problem now is that the new input shaft is loud.... too loud. It sounds like a whine when I go down the treet and it is aggravating as hell. I already swpped new motor old shaft and old motor new shaft etc. to verify it is definitly the new shaft making the noise. I am not sure what to do now. It would seem that I need to smooth the gear to match the old one so they will be quiet together. I can spin the wheels by turning the input shaft with my fingers so there is no more noticable drag, it just whines when driven by the motor. I even spun the wheels by hand as fast as I could but hear nothing. The second the motor is powering the gears they whine. Has anyone dealt with this before?? I know one easy answer is to change the next gear, then that will rub noisy on another and another. I want to avoid spending $700 on all new gears. Has anyone smoothed these out before?

I attached some photos, the new one is on the bottom in pic 1 and the new one is on the left in pic 2. I can't see or feel with tools that fit in the groove any difference but also don't know how to measure something like this anyway. I am sure one a "C" hair different than the other in some way.
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Old 11-15-2011, 08:37 PM   #2
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Default Re: New input shaft is noisy as hell. What to do???

Is the new one factory or aftermarket? I would guess that the angle that the grooves are at on the new gears could be slightly different? call who you bought it from ask them if you can get a different one or exchange it, or if this is normal. So it doesn't make the sound with the original? if the original is fine I would get an OEM replacement. Contact a dealer, I don't see it on shopezgo.
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Old 11-15-2011, 11:26 PM   #3
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Default Re: New input shaft is noisy as hell. What to do???

I would put the new parts back in with prussian blue dye http://www.google.com/products/catal...ed=0CD0Q8wIwAQ on the input gear and drive 15 feet, or enough to get a few revolutions of contact, then take it back apart and have a look. That would tell you what is in contact and where. If I were to guess, I would say the old intermediate gear needs the top of each tooth flattened just a "C" hair. The top of each tooth on the old intermediate gear most likely has a tiny rolled or knurled edge which is contacting the new teeth giving you a harmonic. At the least you would get to play more with the gears and find out interesting stuff. Maybe I'm just a nutball though :)

Last edited by Gonkulor; 11-15-2011 at 11:59 PM.. Reason: added reasoning
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Old 11-16-2011, 05:04 AM   #4
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Default Re: New input shaft is noisy as hell. What to do???

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Originally Posted by Gonkulor View Post
I would put the new parts back in with prussian blue dye http://www.google.com/products/catal...ed=0CD0Q8wIwAQ on the input gear and drive 15 feet, or enough to get a few revolutions of contact, then take it back apart and have a look. That would tell you what is in contact and where. If I were to guess, I would say the old intermediate gear needs the top of each tooth flattened just a "C" hair. The top of each tooth on the old intermediate gear most likely has a tiny rolled or knurled edge which is contacting the new teeth giving you a harmonic. At the least you would get to play more with the gears and find out interesting stuff. Maybe I'm just a nutball though :)
I was thinking of something like that. Wouldn't it be the new gear that needs shaving? The other one would also be hard to
to get to since it is in the middle of the gear box. I read on a RC hobby site one method is to run them with car compound wax in them
let them smooth themselves out, unfortunatly I don't have a way to isolate these two gears from everything else and can't just fill my garbox with compound wax.
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Old 11-16-2011, 08:48 AM   #5
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Default Re: New input shaft is noisy as hell. What to do???

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Originally Posted by jonequest View Post
I was thinking of something like that. Wouldn't it be the new gear that needs shaving? The other one would also be hard to
to get to since it is in the middle of the gear box. I read on a RC hobby site one method is to run them with car compound wax in them
let them smooth themselves out, unfortunatly I don't have a way to isolate these two gears from everything else and can't just fill my garbox with compound wax.
That might work on the plastic or nylon geartrain of an RC car, but it won't do squat on hardened steel gears.
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Old 11-16-2011, 08:54 AM   #6
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Default Re: New input shaft is noisy as hell. What to do???

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That might work on the plastic or nylon geartrain of an RC car, but it won't do squat on hardened steel gears.
Yeah, I guess that makes sense. I was not thinking about the fact that we are dealing with hardened steel. Although if I could have it running on a bench for a couple of hours it woul probably help. I am thinking of letting it free run in my garage for a day but am afraid it will screw other things up running with no load.
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Old 11-16-2011, 09:30 AM   #7
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Default Re: New input shaft is noisy as hell. What to do???

Just a thought, have you counted the number of teeth on each gear? From your photos one looks like it has more teeth than the other. I'd measure the exact diameters of the gears also.
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Old 11-16-2011, 09:31 AM   #8
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Default Re: New input shaft is noisy as hell. What to do???

Don't let it run without a load. You will over rev the motor and melt it down! Someone else did that a couple months ago.

As was said you have some spurs on the gear or it is not shimmed properly that is causing the noise. Bite the bullet and fix it correctly or find a used rear end.

Don't try RC suggestion's, listen to those who work on carts.

Think of us as your "ask the audience" on Millionaire, 8 out of 10 wont be wrong.
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Old 11-16-2011, 11:54 AM   #9
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Even though the new gear teeth are a larger than the intermediate gears worn teeth the intermediate gear was new at one time too. As spawn suggested you aught to bite the bullet and fix it right. I will stand by my suggestion of using prussian blue to find the areas of rubbing and then you would have to take out the intermediate gear to solve the issue whether lapping the gear teeth with valve grinding compound or whatever you decide to do with just the gears out on the bench. Best is to get new but with care and thought, you can get an amiable solution to last a few years if you are trying to save costs. This is just a golf cart after all.

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Old 11-16-2011, 01:22 PM   #10
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Default Re: New input shaft is noisy as hell. What to do???

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Originally Posted by simple man View Post
Just a thought, have you counted the number of teeth on each gear? From your photos one looks like it has more teeth than the other. I'd measure the exact diameters of the gears also.
I thought an extra tooth would just change the speed/torque trade off a bit. However, if this is the case the gaps probably are narrower, which would mean it is a problem. Can you count both?
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