G16A Rear Diff CRACKED

[allergic2sailboats]

Hey guys, a few months ago, I started a thread about how I had Grease filled in my diff instead of OIL. I figured out why, when I pulled the plate off the back of it I realized that the whole case had been cracked.......... by crack the bottom lip of the diff was missing. They RTV'd it and folded the cover back, and crammed grease in there. I was driving it like that for a while, I know it wasn't ideal but I chanced it. The other day my cart starting grinding like of SOB. So I started to take the whole transaxle assembly out of the cart because I am going to get it welded. Took transaxle out and pulled input shaft out, the thrust bearing on the shaft came apart and the little roller bearings were grinding out all the gears. Anyways, I am in the process of fixing this mess. I had to gut the transaxle case, so my buddy could weld it up. I have pictures that I will be posting.

I am slapping on the jakes torque clutch kit. Has anyone went with different gear sets? I was thinking going to 8 to 1, not sure if that would be stupid with a torque upgraded clutch. Is there a way to just order the Bearing on the end of the Shaft? It looks like a thrust bearing with little roller bearings... I ordered the whole shaft because I could not find just that piece.

Let me know what you think.

[allergic2sailboats]

I will be putting better pictures up when I go to re-assemble. I had to pull everything out, so the guy could weld. I am also going to have him put a bung fitting in for a drain hole. It's stupid to me that you have to pull the whole plate off to drain oil. And then RTV... Ain't nobody got time for that! If I did not have a machinist as a friend then I would probably be stuck like chuck, for the diff.

So far I have ordered.. Input Shaft kit. (300 bucks)
Jakes torque clutch kit (100 bucks or so)
Axle Bearings, and Diff Bearings, (45 bucks) The Diff bearings I received are sealed bearings and the ones I took off are not, so I am hoping they are the right ones.

Also. When I took the shaft out, the spacer sleave was stuck on the shaft. I mean FUSED on there I had to knock the shaft out with the bearing on it.


ALSO... these pics are after I took it to the parts cleaner... it probably had 4 tubes of GREASE in there... It was friggin messy.

[cgtech]

man, that thing is gonna be noisey... i bet every gear in there is messed up.

[allergic2sailboats]

The gears themselves are pretty ok. It messed the Big one up a bit, you see indentations of the little needle bearings in it. If I don't change the gear set, I am going to just keep what I got but I will try to stone out the rough marks/burrs and sharp parts.

[Mike Mac]

I''m not a machinist, but everything in there has started to eat itself up. It's not gonna stop!!

And I would think you could find a different rear end for less than $300!!

[allergic2sailboats]

I guess I wasn't clear... The case got cracked from whoever owned it before me. They hit something and cracked it. And Where can I find a rear end for 300 bucks? Please tell me! I saw used ones on craigslist for 600 bucks and it was as is.... so who knows what it looks like inside. I did not want to spend 300 bucks for an input shaft.. but that's what it is... If I could the needle thrust bearing that broke apart I would have figured away to just replace that.. The part manual shows it on the diagram but lists it with the Input shaft. The cart shifted fine until last week, it started grinding so I stopped and tore everything out.. so the damage on the inside is pretty minimal other than that the shaft is bad.

[Mike Mac]

I'm a cabinet maker, not a metallurgist, (and I havent' seen your parts), but the hard facing temper on all the used parts that you put back in there are going to continue to degrade, and destroy any new parts you but in there with them!! I would get a professional opinion, before you spend money!!

[cgtech]

the torrington bearing on the input shaft that came apart is the governor. you could just remove the 3 weights & whatever remains of the bearing, get rid of fork on governor shaft. disable the governor completely. since you are not gonna replace everything, why replace anything? lots of superglue, duct tape & bubblegum, it will live on, Or Else!

[robertakamagoo]

We make splines were I work same as gears. I went a few class on gears. They cost a lot to make. If they wear them out they take everything with them and you loss power. I know on g29 they make the wheel hub spline weak so it will give out before your main gears. I was pulling my cover on mine and change the oil. The rear end is made by a well know gear maker Specer. Angel gears are better more surface contact.some have oil plugs that have magnets on them so they can pick any steel chips. It sucks that you found grease in the pumpkin Its still better than nothing. My pumpkin had some hits.

[Mike Mac]

Here ya go, somebody that knows what he's lookin at!! Post pics and let CG and Robert have a look!!