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Old 11-22-2017, 10:03 AM   #1
Gofigure1
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Default 96 EZGO 36V Clunking sound. Need some help

I'm hearing a clunking sound from the rear of cart when initially pressing throttle and occasionally while driving. I've attached a video with the rear wheels off the ground demonstrating the noise by moving the wheels by hand.
Any help troubleshooting is appreciated.
https://www.youtube.com/watch?v=vTVuL9hSX3E
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Old 11-22-2017, 10:15 AM   #2
mutant
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Default Re: 96 EZGO 36V Clunking sound. Need some help

warning!running it wide open with no load(max rpm) is a good way to explode the motor...

the noise might be the bearings in the diff or the bearing in the motor... also check the hubs-they are bad for stripping the splines...if the axle nut moves on the drum while on the ground you have stripped the splines...
the noise sounds like a bad bearing...you can drop the cover off the bottom of the rearend and inspect the oil for debris...use a pan to catch the contents...
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Old 11-22-2017, 10:31 AM   #3
scottyb
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Default Re: 96 EZGO 36V Clunking sound. Need some help

Sounds like there hasn't been any oil in the differential for some time.
Drop the pan and have a look. I looked in one once that had nothing but shavings and dust in the pan.
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Old 11-22-2017, 06:46 PM   #4
Gofigure1
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Default Re: 96 EZGO 36V Clunking sound. Need some help

Hub splines look fine. I drained the diff and there was a good amount of oil. I did not pull the pan yet to check for debris but the oil looked ok. I pulled the motor and took some pics. The motor bearings sound a little rough so I suspect they need to be changed. I turned the hubs with the motor out and diff bearings sound a little worn as well. Does someone have a drawing of the diff so I can decide if I want to dive in. Also, what kind of bearing puller is required. Thanks
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Old 11-22-2017, 06:48 PM   #5
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Default Re: 96 EZGO 36V Clunking sound. Need some help

Here are the hub pics. I believe they are fine.
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Old 11-22-2017, 08:54 PM   #6
Dixie Chopper
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Default 96 EZGO 36V Clunking sound. Need some help

Do a search for Dana axle. There are a few PDF files of the Dana rear axle service manual floating around on this forum. I canít attach one from my phone sorry

Edit - try this from JohnnieB

http://www.buggiesgonewild.com/attac...5-28148g01.pdf


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Old 11-23-2017, 06:27 AM   #7
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Default Re: 96 EZGO 36V Clunking sound. Need some help

This will help you

http://www.buggiesgonewild.com/elect...tml#post658807
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Old 11-23-2017, 09:36 AM   #8
Gofigure1
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Default Re: 96 EZGO 36V Clunking sound. Need some help

Perfect... Thank you Dixie Chopper and RIB33024 (good pics and guide). Iíll find a shop with a bearing press and give it go.
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Old 11-23-2017, 09:36 AM   #9
scottyb
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Default Re: 96 EZGO 36V Clunking sound. Need some help

Dana Ezgo electric.
Attached Images
File Type: jpg Dana Elec.JPG (111.2 KB, 0 views)
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Old 11-23-2017, 04:03 PM   #10
Gofigure1
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Default Re: 96 EZGO 36V Clunking sound. Need some help

After further review It looks to me like the input shaft from the differential to the motor is leaking oil into the motor. The motor shaft has a slight wobble as well. Is there a way to replace the input shaft seal on the differential without tearing down the whole differential? Opinions on what you all would do? Pics below. Thanks.
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