Yamaha g16 rear axle issue

lady bug

So I just purchased a g16 lifted lights winch top windshield. Got the cart cheap 500 I could see that it's a cobbled mess but plenty inclined to fix the cart. I brought it home it did not run I did a tune up carb clean ect. It smokes like crazy lol so out with the engine rebuilt and installed cart runs great. I ran it for break in purposes and the rear end was very loud. I pulled the plug and was almost empty topped it off checked for leaks and it still wined like crazy. I now pulled sec. Clutch off removed input shafts replace all bearing's. Sprayed it out with carb clean ect. I removed the cover on the back and it revealed a messs. I don't know if the cart sat for a very long time but the gears and bearings are completely full of rust. I am pulling it completely down now to clean and put all new bearing's in it. This is my ? The teeth on the large carrier gear are rough. Not what a clean gear should look like. So I was wondering g this cart is only for trail riding mud ect. Is there anything I can do to the gears like medit blast polish file the teeth just to quit it down. Run a thicker fluI'd? Plus the axle shaft bearing's are like rusted into the rubes I have tried with p.b blast and a hammer for about an hour now any tricks to removing them and yes I have removed the bearing retaining snap rings on the outer axles thank so much everyone.

BGW

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lady bug

I also wanted to add the mating surfaces of the gears seem to be rust free it's the sides of the gears that have rust and pits on them. But the gear teeth look like to me that some large metal has went through them at some point very rough and jagged one tooth Evan has a small piece of metal on it thanks again

cgtech

Ouch, I don't know how you gonna quiet that much damage down. All the rust not on the teeth will come right off with a wire wheel (I would suggest keeping the wire wheel off the gear teeth). One thing I will suggest, silicone a magnet to the inside of the diff cover, below the oil line, that will collect up any junk that gets moving around in there.

Shepard

If your rebuilding this to run and the gear surfaces are good but not perfect -- I would try this product. It's a very light - almost liquid grease used in a outboard engine gear box. Lubriplate #105 gearbox lube.
I use this in my steering box. The engine assembly version has more zinc oxide and would work well in your situation. It will cushion the gears helping to quite them.

http://www.skygeek.com/lubriplate-c1...0-oz-tube.html

Shepard

What type of bearings are in the axle tubes? If it's a taper bearing race or the outside remains of a ball bearing --- if available use your MIG and lay a bead of weld about half way around the race - be careful not to weld it to the tube. After it cools completely -- the bearing should shrink enough to fall out.

cgtech

Sealed ball bearing, not taper roller.

sho305

I can tell you if the gear teeth get worn badly from the bearings being bad, you will never quiet them down. Thicker fluid may help some. Either you put gears in or replace the entire box. If its just rust sure you can wire wheel them, sand blast, put new bearings on the shafts and it should be fine....long as the teeth are ok. I worked on a CC rear that was run dry, the bearings I found as standard sizes but it still made noise. Found the top gears that went dry wore in badly and no good. Luckily those are the gears you replace for HS gears so guess what, that cart was all stock and did 28gps after that lol. They were 300 for the HS gears though.

cgtech

Hmm, good point. The ring gear & it's counter gear is what's replaced for HS gears in a Dana gas axle. But HS gears are not gonna work for trail riding & mud. High torque gears for Dana gas axle? Do they exist?

lady bug

So I got the axles out. Used a slide hammer with a fork on the axle nut and they fought me the whole way but did come out. The gears that were affeted were the ring and pinion all other gears are fine. Inspected and I can't seem to find what broke off and went through them but something steel did for sure. Nice to know I can fix with a new gear set. But I was thinking of trying to do some steady hand and patientce and see if I could take a machinist file to the teeth Evan if it was a little better I would be happy thanks again

lady bug

I have done this exact thing on an ego with mediocre results at best. It did work though just not well lol