clubcar carryall grinding in reverse

bigred4749 · 01-20-2010, 10:13 PM

when cart is in reverse you can ease gas and it will backup but if you gas it hard it will grind like its not all the way in gear .does this sound like it could just be an adjustment issue or deeper problems?

Radicalgolfcarts · 01-20-2010, 10:15 PM

Try and adjust it with the F&R cale if not then its a deeper prob!!

Jigg · 01-21-2010, 09:21 AM

Sounds to me like the synchronizer ring is gone in the rear end. Part number 101981001. I'd suggest new thrust plates too, parts 101892201 (3 needed), 1016337 (1 needed)

bigred4749 · 01-21-2010, 08:22 PM

i think its just adjustment because u can hold f-r handle over and it dosent grind at all even full throtle

Jigg · 01-22-2010, 01:46 PM

Yep, that'll happen when the synchro goes bad. I've done two in the past year or so. Both would stay in gear if you held pressure on the lever, but would pop out if not. No amount of adjustment would hold it in gear.

Try this:

Remove the cable end from the lever on the transaxle. Manually put the transaxle in reverse and try driving. If it pops out of gear, it's the synchro. If it stays in gear, it's the adjustment on the cable.

bigred4749 · 01-23-2010, 01:00 AM

ckiguy · 01-23-2010, 10:21 AM

big red if all is good, and the adjustment fixed the issue, give the axle a fresh dose of lube! if it has the metal debris from the sychros in there, or even other thrash, it will continue to grind away. for less then 10 bucks and 2mins of time i would say its well worth it! and this way you can seethe condition of your old oil and see what is actualy in ther, metal flakes, metal debris, is it brass, copper, stell or just oil! plus it never hurts to have fresh oil in it agter every so long!

bigred4749 · 01-23-2010, 10:49 AM

still grinding since i took cable loose in reverse. how difficult is it to put sycronizers in it

Jigg · 01-23-2010, 01:19 PM

It's not terribly difficult. It's much easier if you have a press though.

Drain the gear oil.
Remove the bed.
Remove all of the cables that go to the transaxle.

Jack the rear end up and place the cart on jack stands (i use the body right in front of the wheel wells), then remove the passenger's side axle tube from the transaxle (which means unbolting the u-bolts). I don't take the wheel or brakes off, just move the tube and all out of the way.

Once this is off, you can remove the bolts holding the case together. Be careful when you pry it off, as the gears will be attached to the case half.

Once you get the case half and gears out... it's pretty self explanitory on how to replace the synchro. It's a matter of removing everything on that gearset leading up to the synchro, sliding the new synchro on, and sliding/pressing it all back on.

I can scan the parts diagram and tech manual on this stuff on monday if you want.

ckiguy · 01-23-2010, 04:52 PM

hey big red here is a service manual for a 97 ds. i have a 99 carryall and it works for everything i needed. it does have the rear axle info in it. it has the tear down and repalcemnet procedure in it. its the 3rd posting, and you can save it to your pc and print off
http://www.buggiesgonewild.com/gas-c...ir-manual.html

01-20-2010, 10:13 PM	#1
bigred4749 Not Yet Wild Join Date: Jan 2010 Location: lake city,fl Posts: 65	clubcar carryall grinding in reverse when cart is in reverse you can ease gas and it will backup but if you gas it hard it will grind like its not all the way in gear .does this sound like it could just be an adjustment issue or deeper problems?

01-20-2010, 10:15 PM	#2
Radicalgolfcarts Gone Wild Join Date: Jun 2008 Location: LINWOOD, MI Posts: 1,362	Re: clubcar carryall grinding in reverse Try and adjust it with the F&R cale if not then its a deeper prob!!

01-21-2010, 09:21 AM	#3
Jigg Not Yet Wild Join Date: Jan 2010 Location: Clinton, MA Posts: 14	Re: clubcar carryall grinding in reverse Sounds to me like the synchronizer ring is gone in the rear end. Part number 101981001. I'd suggest new thrust plates too, parts 101892201 (3 needed), 1016337 (1 needed)

01-21-2010, 08:22 PM	#4
bigred4749 Not Yet Wild Join Date: Jan 2010 Location: lake city,fl Posts: 65	Re: clubcar carryall grinding in reverse i think its just adjustment because u can hold f-r handle over and it dosent grind at all even full throtle

01-22-2010, 01:46 PM	#5
Jigg Not Yet Wild Join Date: Jan 2010 Location: Clinton, MA Posts: 14	Re: clubcar carryall grinding in reverse Yep, that'll happen when the synchro goes bad. I've done two in the past year or so. Both would stay in gear if you held pressure on the lever, but would pop out if not. No amount of adjustment would hold it in gear. Try this: Remove the cable end from the lever on the transaxle. Manually put the transaxle in reverse and try driving. If it pops out of gear, it's the synchro. If it stays in gear, it's the adjustment on the cable.

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01-23-2010, 01:00 AM	#6
bigred4749 Not Yet Wild Join Date: Jan 2010 Location: lake city,fl Posts: 65	Re: clubcar carryall grinding in reverse 10-4

01-23-2010, 10:21 AM	#7
ckiguy Bad *** Speller! Join Date: Oct 2009 Location: Columbus, Ohio Posts: 1,338	Re: clubcar carryall grinding in reverse big red if all is good, and the adjustment fixed the issue, give the axle a fresh dose of lube! if it has the metal debris from the sychros in there, or even other thrash, it will continue to grind away. for less then 10 bucks and 2mins of time i would say its well worth it! and this way you can seethe condition of your old oil and see what is actualy in ther, metal flakes, metal debris, is it brass, copper, stell or just oil! plus it never hurts to have fresh oil in it agter every so long!

01-23-2010, 10:49 AM	#8
bigred4749 Not Yet Wild Join Date: Jan 2010 Location: lake city,fl Posts: 65	Re: clubcar carryall grinding in reverse still grinding since i took cable loose in reverse. how difficult is it to put sycronizers in it

01-23-2010, 01:19 PM	#9
Jigg Not Yet Wild Join Date: Jan 2010 Location: Clinton, MA Posts: 14	Re: clubcar carryall grinding in reverse It's not terribly difficult. It's much easier if you have a press though. Drain the gear oil. Remove the bed. Remove all of the cables that go to the transaxle. Jack the rear end up and place the cart on jack stands (i use the body right in front of the wheel wells), then remove the passenger's side axle tube from the transaxle (which means unbolting the u-bolts). I don't take the wheel or brakes off, just move the tube and all out of the way. Once this is off, you can remove the bolts holding the case together. Be careful when you pry it off, as the gears will be attached to the case half. Once you get the case half and gears out... it's pretty self explanitory on how to replace the synchro. It's a matter of removing everything on that gearset leading up to the synchro, sliding the new synchro on, and sliding/pressing it all back on. I can scan the parts diagram and tech manual on this stuff on monday if you want.

01-23-2010, 04:52 PM	#10
ckiguy Bad *** Speller! Join Date: Oct 2009 Location: Columbus, Ohio Posts: 1,338	Re: clubcar carryall grinding in reverse hey big red here is a service manual for a 97 ds. i have a 99 carryall and it works for everything i needed. it does have the rear axle info in it. it has the tear down and repalcemnet procedure in it. its the 3rd posting, and you can save it to your pc and print off http://www.buggiesgonewild.com/gas-c...ir-manual.html

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