rebuild of differential

sonnysmith

Has anyone got a break down on rebuilding the rear end of an ez go 2000 model. I don't know if you have to set the back lash or any other setting.
How do you know what part is making the noise,Mine make a noise only when NOT under a load.

Thanks all
Sonny

BGW

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ORTitan

There is no option to set backlash on any of the gears in that transaxle. The "ring and pinion" are helical gears, not hypoid style like you are used to seeing in an automotive diff. Most often the whine or rattle noise is coming from worn splines on the input shaft/motor coupler.

sonnysmith

Thanks for the reply.
They do look a bit worn.
Is there anyway you can tell what is worn? Mine look like the motor,or female end is worn,but not real sure.Is there a test,other than knowing what to look for,I can do???? I know this is like asking how long is a piece of string.
But, I'm just not sure how much slack is to much.

Thanks for the help.

ORTitan

Splines should have no noticeable play when rotated against each other when they are new. As they wear more slop or play will occur. This can make the noise.

The picture here is of a worn EZGO input shaft just like what you should have in your cart. Notice how the area at the bottom end of the spline is larger in diameter and is unworn. This shaft was bad enough that it required replacement.

When the coupler and shaft look like this it will be very noisy when coasting and will strip. When this happens your motor will run, but the cart will not move.

Hope this helps.

sonnysmith

Mine is not that worn,but has some. The next question is the motor part.Is the coupler made on the armature or can they be replaced.Mine looks like it could also be worn.
I sure have lots of question, and thanks for the replies.

sonny

ORTitan

Your cart should have an AMD motor in it stock. For that motor the female spline coupler is pressed on to the armature shaft. It is replaceable... However it is a bit of work to do it. A new coupler is available aftermarket.

If you had plans of upgrading your motor in the future then it could be better to save your money for that. The couplers are around $100.00. Add to that some machine work to get the old coupler off.

sonnysmith

Thanks
I guess, I'll go into the thinking mode for now,not sure what I want to do.
Just don't want to spend alot of money on the cart.

Sonny

yurtle

Owner's, Parts, and Service Manuals:
http://www.buggiesgonewild.com/elect...g-manuals.html

Dana Axle:
http://www.buggiesgonewild.com/attac...5-28148g01.pdf

I replaced all bearings and seals and used a 90 weight gear oil with a touch of STP and that quieted my '98 rear-end up.

I stuck a strong magnet in the used oil and left it overnight. I didn't find any significant metal "dust". If you find something like another post that was running dry, then you need to rethink this.

sonnysmith

Yurtle,I think my noise is coming from the input shaft and/or motor spline.
There in no wear in the rear end that I can tell.Just the noise when I let of the gas.
Thanks for the reply.