G2 Gas Rear End Broken Gear Teeth/Chattering

Xtreme Cartz · 07-12-2010, 08:05 PM

I was out driving my cart today when a sudden loud chattering began in the rear end. I took the belt off to spin the secondary by hand. There are rough spots and it makes a loud metal chattering sound. I decided something was seriously wrong and decided to pull the rear end. I drained the oil and it looks grainy. When I split the rear end apart the first thing I noticed were broken teeth on the two main gears. Underneath the spider gear assembly was a pile of broken metal shrapnel. I am not able to tell what the carnage is from exactly. The only recognizable piece looks like a washer. The gears must have churned the debris up and thats how they broke their teeth? I might be lucky and have some parts from a spare g2 diff. Any ideas what happened and what needs to be replaced? I will post some pics.

Xtreme Cartz · 07-12-2010, 08:18 PM

Broken Debris

Grainy oil

Chipped Gear teeth

Are these gears suppose to not touch?

Thanks

Xtreme Cartz · 07-12-2010, 11:20 PM

Is there a blow up diagram for the g2/g9 rear end? I really need help and cant find much info. Thanks

Edit-was able to find a diagram on another site. Still wondering where that debris came from?

ace_ripper · 07-13-2010, 01:53 AM

Quote:

Originally Posted by Xtreme Cartz

Is there a blow up diagram for the g2/g9 rear end? I really need help and cant find much info. Thanks

Edit-was able to find a diagram on another site. Still wondering where that debris came from?

OOUCH!!!

Been there on Toyota pickups. Not sure what caused yours, but I do have a service manual if that would help at all. Just get me your email and I'll send it right over.

Best of luck with the rebuild!

Xtreme Cartz · 07-13-2010, 02:06 AM

Ohh did you say toyota pickups?

My baby is a 91 4x4 just got a new reman 22re engine, camper top and paint job!

smallblock450sl · 07-13-2010, 06:42 PM

Is this the rear end your welded the spider gears? That looks like one of the "thrust washers" for input of f/r gear shafts, that doesn't make sence. Did you use a gasket (for case halves) or RTV? Did you bypass the govenor? Did you take out the govenor weights/fork? Good pix's but wish I was there to help. Keep us posted.

Xtreme Cartz · 07-13-2010, 07:21 PM

Yes it's the rear end with the welded spiders. I used RTV to seal the case. I did remove the governor weights. Last time I had this diff apart was to take out the high speed gears and reinstall stock gears. The washers tend to fall off the shafts when I split the case apart. All I could think possibly happened was I missed one that fell under a gear?

07-12-2010, 08:05 PM	#1
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	G2 Gas Rear End Broken Gear Teeth/Chattering I was out driving my cart today when a sudden loud chattering began in the rear end. I took the belt off to spin the secondary by hand. There are rough spots and it makes a loud metal chattering sound. I decided something was seriously wrong and decided to pull the rear end. I drained the oil and it looks grainy. When I split the rear end apart the first thing I noticed were broken teeth on the two main gears. Underneath the spider gear assembly was a pile of broken metal shrapnel. I am not able to tell what the carnage is from exactly. The only recognizable piece looks like a washer. The gears must have churned the debris up and thats how they broke their teeth? I might be lucky and have some parts from a spare g2 diff. Any ideas what happened and what needs to be replaced? I will post some pics.

07-12-2010, 08:18 PM	#2
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: G2 Gas Rear End Broken Gear Teeth/Chattering Broken Debris Grainy oil Chipped Gear teeth Are these gears suppose to not touch? Thanks

07-12-2010, 11:20 PM	#3
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: G2 Gas Rear End Broken Gear Teeth/Chattering Is there a blow up diagram for the g2/g9 rear end? I really need help and cant find much info. Thanks Edit-was able to find a diagram on another site. Still wondering where that debris came from?

07-13-2010, 02:06 AM	#5
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: G2 Gas Rear End Broken Gear Teeth/Chattering Ohh did you say toyota pickups? My baby is a 91 4x4 just got a new reman 22re engine, camper top and paint job!

07-13-2010, 06:42 PM	#6
smallblock450sl Sometime's............ Join Date: Oct 2007 Location: Tacoma Washington Posts: 11,874	Re: G2 Gas Rear End Broken Gear Teeth/Chattering Is this the rear end your welded the spider gears? That looks like one of the "thrust washers" for input of f/r gear shafts, that doesn't make sence. Did you use a gasket (for case halves) or RTV? Did you bypass the govenor? Did you take out the govenor weights/fork? Good pix's but wish I was there to help. Keep us posted.

Today
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07-13-2010, 07:21 PM	#7
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: G2 Gas Rear End Broken Gear Teeth/Chattering Yes it's the rear end with the welded spiders. I used RTV to seal the case. I did remove the governor weights. Last time I had this diff apart was to take out the high speed gears and reinstall stock gears. The washers tend to fall off the shafts when I split the case apart. All I could think possibly happened was I missed one that fell under a gear?

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