I’m getting ready to change out the gears to a 15:1 from a 10:1. Are there any “gotchas” I should be aware of?
While apart I have some new rubber boots to install for the half shafts and the book says I need two special tools for the clips. Is there a good work around without those tools?
Thanks in advance!
Have you seen Grants’ video on how to take it apart?
It is like one of those cooking shows where he doesn’t actually show you some of the struggle, but gives you some idea what you will be dealing with.
I have not tackled a halfshaft on a GEM, but have on other cars. I’ll take a look in the manual and find that section that suggest the special tools.
Yes I did see that video, thanks… I also looked for the one where he put it back together but didn’t exist me thinks.
So the parts kit I got for the broken boot came with some new bands. At least on that side I can just cut them off I think…
Still not sure about the rest but I have the front jacked up and on stands, the battery box off and taking is slow…
My goal is to take it all out in one piece if possible and that take it to my mechanic friend’s house for the change out. Learning all I can as I go…
I am sure I will have more questions…
Please let me know about those tools…Thanks!
The C clips/lock rings?
You can grind a pair of needle nose pliers or you can just splurge on $18.
Half shaft boots need a banding tool. I have a cheap one… they suck. It was a waste of money…
I have snap ring pliers… that is not an issue… it’s the banding pliers.
So I got it all apart! Woo Hoo! Taking the box and new gears to my buddy’s house in a couple of hours… should be putting it all back together later today. I’m thinking the banding pliers are my issue now. I think I will figure a way around them… doesn’t look that tough… (famous last words).
At least now I can clean where the pressure washer didn’t get to before… But this time it has to be all cleaned by hand… it’s stuck inside.
Got it done… But OMG… I would have never been able to do it on my own. My buddy had so many tools that I do not have, including the hydraulic press.
That tear down video was only somewhat helpful. We couldn’t make it happen the way he did.
Now I just have to figure out how to put oil in it… ha ha…
For the amount and speeds you are planning, I bet you can just use a couple/three wraps of SS wire and twist.
If you are really set, Let me look for my set and I’ll loan then up to you.
Otherwise, I’ve been thinking about adding a set of these to my toolbox.
See Clamptite
Did you take a video of the process.
I have to see if HF has any tensioning tools. Gotta go there anyway.
Sorry I did not do any video. We both had our hands dirty with all the oil and crap. It was a bit of a mess until we got the gears out and were able to clean everything. I took a pic of the finished box before we closed it up and also the GEM in pieces… ha ha
That clamp tool looks pretty cool, but I hope I only need to do this once!
How do you get oil in the differential?
There should be a fill / drain bolt on the pumpkin.
Manual calls for 10-30. That will get you more range. Most of us run (ran) 85-90 in those old gems to quiet them down.
Fill volume by what the manual says not by where the hole is
no bolt. there is a rubber stopper kinda thing on the bottom… I guess I could fill it there… I haven’t put it can in the frame yet but it looks like that plug would just leak back out… I’ll have to check… If it is on enough of an angle it could work but it will be a transfer pump thing…
Manual says SAE 30 16oz
About the size of a quarter? On the pumpkin cover? That’s it.
I wrote bolt without thinking. Been working on the cushman hauler at work…
If its in the original mounting position the oil come up just to the bottom of the plug on 00-04
30 is fine it depends how quiet you want it. 85-90 will will keep the chatter down at high speed.
Most of us pushed our gems faster. Youre going the other way. You can almost do no wrong. These buggers dont break when they go slower than the design spec. We all wanted to go 35, even 40-45mph.
I busted a lot of ■■■■ trying to break 40 in my old style carts.
it is whining at low speeds now with the new gears. I am assuming… that will go down with some break in time…
Where did this gear set come from? Usually gear whine is not kick in until you get up in speeds.
Did you put in 30wt? Use gear lube. Put in some some motor honey too
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came from Ride 4 Fun. Yeah these growl from the start.
I did use 30wt… but going to pump it back out and go heavy and looking for that “motor Honey” stuff.
