EZGO Marathon - Rear Axle Play (HELP!)

[Lee0]

Hey y'all,

Used to be a member of this forum before and bought a full kit from CU/ScottyB earlier this year (definitely recommend going to him!) Back with a question but can't remember my profile info so created a new account.


I'm rebuilding a 1991 EZGO Marathon. This past weekend I cleaned up the rear diff internals (gears teeth looked fine), replaced the rear axle outer bearings and diff output bearings. Everything seemed to go alright. Putting everything back together I'm getting some play in the driver side axle (in-out axial movement; no lateral/side-side/up-down movement - just "in and out" in the axle direction).


I re-pulled the axle and the bearings seem snug up to the flared section/stopper on the axle. New snap rings installed and are in place. Castle nut torqued to 125ft.lbs. Still getting in and out play. Probably 1/4" of play. I did re-use the original thrust washers. They were worn/grooved ever so slightly but no more than a fraction of a mm so although not ideal I doubt leading to the 1/4" of play.


Any ideas?


The outer axle bearings between the two snap rings are the only retainers I imagine. I'm assuming when I push/pull the axle maybe the axle is slipping in the bearing on the inward push and maybe getting stopped by the spider gears and then when I pull it outwards slides back into the bearing and hitting the retainer? The bearing is pressed on but I can get it back off the axle "relatively" easy when compared to how hard the originals were to get off. Maybe I got a bearing with a bad tolerance (cheapo amazon china 1O1O ones).


Suggestions appreciated before I buy new bearings.


Pics of the cart attached for fun but not related to the issue.

[Lee0]

For extra build info for those curious:

• D&D High Speed & Torque Series Motor (bought used)

• Alltrax SR48500 Controller

• 400A HD Solenoid

• SW202 HD F/R switch

• 2g cables

• 21x7.00-10 / 22x9.00-10 ATV wheels & tires

• 2" front wheel spacers (China Brand)

• 5" lift kit (China Brand)

• HD rear springs (one leaf removed)

• 2003 EZGO front leaf springs (3in longer)

• 2008 EZGO roof & windshield (free takeoffs from a company that does custom builds)

• Front & Rear Shocks (China Brand)

• Truck bed light (underglow) (China Brand)

• Pod headlights (China Brand)

• Rear seat grab handle (China Brand)

• Custom made bolt on triangular rails (to keep the kids in rear seat)

• Vinyl spray paint for the seats (works really well surprisingly!)

• Fast & Furious R32 skyline inspired graphics courtesy of my wife and her Crikcut

• New bearings front & rear (China Brand)

• New brake pads & drums (China Brand)

• 6 x 8v Interstate GC8 batteries

• Bunch of other small little accessories

Performance

Flat Ground

• ~21mph (gps) - Loaded with people/cooler

• ~23mph (gps) - just me

"steep" hills

• ~16mph (gps) - loaded with people/cooler

• ~18mph (gps) - just me