Started the gear change today and I though I'd document what I'm doing for any one that hasn't been inside of one of these rear ends. The gears came with zero instructions so hopefully this will help someone in the future. These rear ends are super simple and anyone with a little mechanical ability can do this. The only sort of specialized tools needed are a pair of snap ring pliers and a torque wrench. Thanks to Scotty for holding my hand long distance thru the entire process the first time I ever did this!!!
I'm starting with the basic EZGO electric Dana rear end. This particular one is a 1997 model but they are pretty much the same from 1988 up. I have already removed the brake drums and backing plates so you are on your own on how those come off.
The first order of business was to remove the cover and drain the oil. Then we move onto removing the axles. They are held in with snap rings.
You simply remove the snap ring with snap ring pliers and the axles should pull out with the bearings intact...except for they always seem to be stuck big time in the housing. Scottyb truned me onto remounting the brake drum backwards onto the axle so you can hit the face of the drum using a dead blow hammer to drive the axle out. Works like a charm!
These were really stuck. I was beginning to wonder but they finally popped loose.
Once the axles are removed, there is yet another snap ring and then the axle seal. I'll remove and replace all of these parts. EZGO services these in kits that have the bearing, seal and new snap rings all in one package.
This is how I've figured out to remove the bearings from the axle shaft. Maybe not the right way but it works for me. I open up my bench vise wide enough to support the edge of the bearing and set the axle in the vise. Do not clamp the vise down on the axle. You will damage it!! Just let the jaws of the vise support the bearing and take a block of wood and place it on the end of the axle and hit the block of wood with a hammer driving the axle out of the bearing.
Next we move onto getting the differential carrier out of the housing. It is held in with 2 bearing caps which have 2 bolts each. This is where you will need the torque wrench when you put it back together. These bolts torque to 40ft/lbs. It may not be absolutely necessary, but I like to reinstall the bearing caps back in the same orientation as they came out so I'm careful to keep them straight once they are removed.
Heres the differential carrier out of the housing. These bearings just slide off the shafts. One of these bearings felt like it had a little catch every once in a while when I spun it so I will be replacing all of the bearings after all. You can order them from one of the forum sponsors or from EZGO but I opted to take the old ones to a local bearing house and get replacements there.
More in the next post....