HELP!!!! Ezgo gear change

ronncat

Accidentally posted this in the CC section

I'm at the machine shop now. Having my gear pressed off the intermediate shaft and onto the new one. There is a pin driven into the old one, probably for anti-rotation. There is no provision for this pin on the new gear. Is this necessary, or will the friction of the gear press fit keep it from rotating. The machine shop is telling me they would have to EDM a notch into the new intermediate gear because it is so hard. So... Leave it off or have them machine a recess for a pin. HELP!!!! I need to let them know. Thanks!!!

BGW

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sportcoupe

No need to worry about the pin, press the new gear on and reinstall. I ran into the same thing when I did 6:1 gears on my own cart. Never had an issue and it runs 36 mph and has tons of torque.

ronncat

Thanks for your input

I ended up leaving the gears at the machine shop. We measured the old and the new gear. The old one had an interference fit of 2 thousandths. The new gear is 2 thousandths smaller in diameter than the old. This would result in a zero clearance fit. Was scared that the gear could turn on the shaft. The machinist is going to show it to another coworker and they'll try to figure out a solution. One was to use the EDM to burn a slot into the new gear for the pin and the second was just to run a few tack welds on the completed assembly. Any opinions???

Sir Nuke

ahhhhhh, I think you're confused.....the old one has a .002 interference fit.....and your NEW gear is .002 SMALLER. (bore diameter) where it is pressed onto the shaft.....which means it would have a .004 interference fit.....not a ZERO clearance fit, and no smaller than the shaft is, you would be very hard pressed to even be able to have it pressed on without damaging it.

ronncat

errr sorry....

I may not have described the situation quite right. When replacing the gear, the part that actually gets changed is the smaller gear of the intermediate gear assembly which is machined on the shaft. The larger pressed on gear that meshes with the input gear is transferred to the new intermediate gear shaft assembly. The shaft of my new gear is 2 thousandths smaller than the oem one which means we'll lose that much in the interference fit. (p.s we may be speaking in ten thousandths)

sportcoupe

Scroll down to post #28 and #29.

http://www.buggiesgonewild.com/elect...eriment-3.html

Sir Nuke

AHHHHH I gotcha!! the SHAFT is .002 smaller....not the gear, so your right....you want from a .002" interference fit to a .000 tolerance fit.

ronncat

Yep... you got it.

So EDM the shaft and place a pin or place a few welds on the shaft/gear to keep it from spinning???

Sir Nuke

if it were me....I would modify the gear....ya never know when you might need to remove the gear.....Murphy might show up at your house....he shows up at mine now and then! LOL NOT TO MENTION....depending how who is doing the welding....if they get things to hot, it will damage the shaft/gear as it could change the properties of the two pieces AND set up some stress raisers in the area of the weld.

ronncat

I think I agree with you. I hope the machine shop can do the mod. I'll find out next week.