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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 08-28-2014, 08:18 AM   #1
mrphilf
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Default Marathon Posi

I've been messing with this for a month or so now and decided to share what I have learned in case anyone else wants to try this. This has all been done on a 1991 Marathon.

Based on an old post here and my old car experiences I decided to shim pack the spider gears in my open differential to bind them up, hence making a homemade posi. I found a carrier on ebay cheap and bought it so if I boofed something I would still have a good carrier.

My first issue was finding shims the right size. I was able to locate some close at a local off road truck builder (random used pinion shims from his old shim box) and machined the ID myself to fit, the OD was an almost exact fit so I left it alone.

I packed the spare carrier as tight as I could get it and still assemble it properly. This resulted in .0015 play being left in the side gears. This configuration worked fairly well, I would say I had both wheels spinning about 60-70% of the time where they normally would have broke loose. I was able to go through some swampy area pretty easily that previously I could never get through. However I was still breaking one wheel loose on some muddy inclines. Upon removing this carrier after about 40 hours of heavy off road usage the spider gears showed definite new wear and I had a fair amount of metal shavings. I concluded this was because I did not pack the gears evenly, I only packed one side.

My second and current configuration was to pack the side gears tighter, in order to do this I needed to assemble the carrier without the smaller spiders thrust washers. By doing this I was able to get the side play down to about .0003. I was careful this time to pack the sides as symmetrical as possible. Unfortunately being packed (like the last time) I couldn't turn the gears by hand to check the mesh pattern. I have now run this set up for about 25 hours of heavy off road use and pulled the diff cover off last night to check things out. I had no detectable metal in the fluid and could not see any any new wear on the spider gears.

I have not lost any speed, my braking power has increased slightly (obviously) and I have yet to be able to break a wheel loose in forward or reverse. I haven't experience any steering problems. Interestingly I haven't experienced any tire skip...thought I would. Not sure if I got lucky on the second try and got the setup just right where the spiders turn when the cart turns but not when straight pulling or not but it sure seems that way. It also may be that the tires are skipping slightly but because they are knobby tires and I'm always off road in the dirt it just isn't noticable.

If anyone else is playing around with this stuff I hope this info helps.
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Old 08-28-2014, 09:14 PM   #2
coosa
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Default Re: Marathon Posi

Interesting post! I once considered trying something similar since I had an extra rear end, but never got around to it. Good to know that it's possible.
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