Mounting upgraded controller

[Wahoouva2]

I just recently bought a 1997 EZGO TXT 36 volt. It has an upgraded speed motor but needed to replace the controller. I bought an upgraded controller, Alltrax AXE 4855. However, I cannot get it to mount to where the old one came off. There is a bracket that had the silonoid on it and there is a bolt mounted at the bottom left and the top right. These are causing it to not line up.

Is there something I am missing as to how to mount it? None of the holes seem to line up.

[scottyb]

Use the center 2 holes and 4 self tapers for the four corners. THe solenoid mounts to the 4855 in the plastic license plate nuts. Ditch the old cover and solenoid bracket.

[JohnnieB]

Here are some pictures of a DCX400 mounted on the heatsink. It has a 6.5" case and an AXE4855 has a 8.5" case, but the mounting hole spacing is the same. The case is simply 1" longer in length in each direction.

The center slots match up the the two holes about midway down the heatsink. Other than those two, none of the other original holes are used and holes have to be bored for the other four mounting bolts.

The two broken off bolts will need to be removed or cutoff flush.

Also, remove the glued on heatsink pad and apply heatsink compound to the cleaned raise surface.

[scottyb]

His solenoid bracket won't match the dimensions of the custom bracket shown. He is best off following the advice I gave above.

[Wahoouva2]

I am unable to get it to line up with the center wholes because of the bolts/posts that are sticking up out of the bracket from the back, see pictures. It is too long to fit in between these two. Do these come out? Are these normally there?

Thanks!

[Wahoouva2]

And here is the bottom one sticking out...

[Sir Nuke]

Just something to think about .... the heat sink is aluminum .... and you can see that it is a bit oxidized ..... if you decide to remove it, for cleaning or to bead blast it, there are 4 bolts on the bottom and most likely, one or more will break off. As when they were put together, no anti-seise was ever used.

The same thing can happen to the studs you mentioned.

The Master of All Things has Spoken

[Wahoouva2]

I am sorry to sound niave, what is the heat sink? Thanks for your insight.

[mazdawg(Mikey)]

The heat sink is the bracket you are posting pictures of. It is made of aluminum and has fins on the backside to dissipate heat. Like what was mentioned earlier the stud you are talking about is a bolt that the head is broken off of. You need to cut that off flush with the heat sink or just buy a new heat sink all together. They are $30ish new. Mine has several bolts broken off so they were cut flush. Mine has self tapping screws holding the electronics onto the heat sink and work just fine