Install a new PQ Executioner motor here is my plan

[aussiecart]

Ok, first part = motor is off now to fix that bloody oil leak.

Please check out the pictures and let me know what you think. I bought this cart new in late 2007 and the motor has never been off. I want to fix this oil leak before the PQ motor goes on.

Is the Plug Cap on back to front and does that matter? I have a new one to install. Not sure if oil is leaking around the plug cap or not because there is oil everywhere in here.

Oil looks like it is leaking around the input gear, I do have some new O'rings, however, not really sure if that will be the problem?

I note on the Dana Axle Manual there are O'rings behind the bearing (motor side)? It also looks like there are O'rings on the axle housing? Which one is more likley the problem?

Do I pull the bumper spline out of the old motor to use in the new motor?

I would appreciate anyones advice that his faced this problem, thanks.

[scottyb]

IN picture #2 there looks to be oil sitting on the lip of the drive spline housing ..... I'm gonna guess the o-ring behind the bearing is the culprit here. Remove the C-clip and the shaft with bearing should come out fairly easy with that much oil present.

[aussiecart]

Ok, took the input shaft out (came out easy), O'ring looked ok but I oiled up a new O'ring and replaced it anyway. Checked input shaft and it all looked good and put it back in. I was worried that the O'ring looked good that I thought maybe I should look at the plug cap just to be sure.

Pulled the plug cap and that sucker almost fell out, there was no sign of gasket sealant on the plug cap anywhere, maybe it wasn't sealed correctly, anyway I put in a new one and used gasket sealant. I decided to replace it the same way as there is not a lot of room there. Everything is ready now for when my PQ motor arrives and then I can install it, oh and yes Scotty the 500a controller and HD solenoid shouldn't be that far away either.

Hopefully I have fixed that oil leak.

[aussiecart]

Well, patiently waiting for my PQ motor to arrive and the postman leaves a box.... not the motor but a little package from Scotty (500a Alltrax Controller and HD Solenoid). Well the temptation was there to run out and start the install, but I thought I would take my time, here is my plan for installing the controller/solenoid, How does it read? Have I forgotton anything?

Steps to installing a new 500A Alltrax Programmable Controller and HD Solenoid to a 2007 Ezgo TXT PDS

Removal of existing original controller
1) Raise cart and place jack stands under rear axle
2) Flick run/tow switch to tow
3) Disconnect battery cable to ensure there is no power to the controller
4) Remove Heatsink cover (double check run/tow switch is still in tow)
5) Take plenty of photos to use as a reference later if needed
6) Label all cables, also write down where they go
7) Remove Solenoid and solenoid bracket
Remove Controller
9) Observe wiring conversion from Curtis to Alltrax controller
Curtis DCS/PDS Alltrax DCX Function
A1 M- Controller output to motor A1
B- B- Battery negative terminal
A2/B+ B+ Battery positive from solenoid & motor A2
F1 F1 Motor F1
F2 F2 Motor F2
10pin 10pin Control wiring

Install of new Alltrax Programmable Controller
1) Fit Controller
2) Fit Solenoid
3) Ensure all terminals and connectors are clean
4) Attach cables double checking cables are in correct location
5) Make sure diode is installed across the Solenoid (striped end toward the positive activation wire (yellow)
6) Recheck that the diode is oriented with the stripe toward the positive side of the activation wires
7) Cut the controller cover in half
Install the controller cover, take care not to fold or short any wires
9) Install fuse between the negative battery cable and battery pack (install at battery for easy access)
10) Reconnect battery cables
11) Wait for at least 30 seconds after power is connected to switch run/tow toggle back to run
12) Test drive

[gornoman]

Originally Posted by aussiecart

Well, patiently waiting for my PQ motor to arrive and the postman leaves a box.... not the motor but a little package from Scotty (500a Alltrax Controller and HD Solenoid). Well the temptation was there to run out and start the install, but I thought I would take my time, here is my plan for installing the controller/solenoid, How does it read? Have I forgotton anything?

Steps to installing a new 500A Alltrax Programmable Controller and HD Solenoid to a 2007 Ezgo TXT PDS

Removal of existing original controller
1) Raise cart and place jack stands under rear axle
2) Flick run/tow switch to tow
3) Disconnect battery cable to ensure there is no power to the controller
4) Remove Heatsink cover (double check run/tow switch is still in tow)
5) Take plenty of photos to use as a reference later if needed
6) Label all cables, also write down where they go
7) Remove Solenoid and solenoid bracket
Remove Controller
9) Observe wiring conversion from Curtis to Alltrax controller
Curtis DCS/PDS Alltrax DCX Function
A1 M- Controller output to motor A1
B- B- Battery negative terminal
A2/B+ B+ Battery positive from solenoid & motor A2
F1 F1 Motor F1
F2 F2 Motor F2
10pin 10pin Control wiring

Install of new Alltrax Programmable Controller
1) Fit Controller
2) Fit Solenoid
3) Ensure all terminals and connectors are clean
4) Attach cables double checking cables are in correct location
5) Make sure diode is installed across the Solenoid (striped end toward the positive activation wire (yellow)
6) Recheck that the diode is oriented with the stripe toward the positive side of the activation wires
7) Cut the controller cover in half
Install the controller cover, take care not to fold or short any wires
9) Install fuse between the negative battery cable and battery pack (install at battery for easy access)10) Reconnect battery cables
11) Wait for at least 30 seconds after power is connected to switch run/tow toggle back to run
12) Test drive

Make sure that only the high current cable passes through this fuse. The other smaller ground wires that attach to the main pack Negative should go DIRECTLY to the battery post ON TOP of the fuse.

[rabbitreborn]

curious Gorno..... Why not connect the control wiring on the fused side?

[gornoman]

Originally Posted by rabbitreborn

curious Gorno..... Why not connect the control wiring on the fused side?

Because the fuse is a 250 amp slow blow and the control wiring will burn up LONG before that fuse even thinks about letting go. I won't put 20 amp circuitry on 250 amp protection.

[rabbitreborn]

ok good point. Never really looked it from that point of view.

[aussiecart]

International shipping is fast from the US these days
Some would even say that the shipping is just "plum quick"

Now I wonder what will I be doing this afternoon?

[essness]

That's the "special packaging" you got there Aussie