DIY Gear Box Refurb Parts

Do It Yourself (DIY)
1

Below are 2 parts lists for refurbing GEM Gear Boxes.

Parts required to refurbish 8.9 and 10.35 Gear Boxes with New Seal Type input shaft assembly

(2) Axle bearing 6004 2RS 20x42x12 MM $2.44 ea
(2) Differential carrier bearing 6007 RS (remove seals)35x62x14 MM $6.46 ea
(2) Intermediate shaft bearing 6303 RS 47x17x14 (remove seals) $3.71 ea

(1) Input shaft kit (Seal type) Includes bearings $190 27 TOOTH.
(1) Input shaft bearing 6005 RS 25X47X12 (remove seals) $3.67 EA.
(1) Input shaft small bearing 6203 2RS 40x17x12 (remove seals) $1.28 ea
(1) Input shaft seal 25X47X6 $4.00 ea.

(2) Intermediate shaft seal cap (freeze plug) EZGO part #601064 From any EZGO Dealer or Orange County Monster Cart. $4.12 ea.
(2) Axle Seal 24x40x10 MM $4.69 ea
(1) Tube Permatex Blue $7 Any auto supply store

All parts available on Ebay except as noted

Parts list to refurbish 8.9 and 10.35 and 12.44 and 14.76 GEM Gear Boxes With Old style input shaft.

(2) Axle bearing 6004 2RS 20x42x12 MM $2.44 ea
(2) Differential carrier bearing 6007 RS (remove seals)35x62x14 MM $6.46 ea
(2) Intermediate shaft bearing 6303 RS 47x17x14 (remove seals) MM $3.71 ea
(1) Input shaft small bearing 6203 2RS (remove seals) 40x17x12 $1.28 ea
(1) Input shaft big bearing NTN6005LLU 25x47x12 $25.89 This IMHO is the only bearing currently available that holdS oil.
(2) Intermediate shaft seal cap (freeze plug) EZGO part #601064 From any EZGO Dealer or Orange County Monster Cart. $4.12 ea.
(2) Axle Seal 24x40x10 MM (CHECK THICKNESS) $4.69 ea
(1) O’ring you only need 1 intermediate shaft has the caps Viton Oring #133 1 13/16" id x 2" od bag of 10 $6.20
(1) Tube Permatex Blue $7 Any auto supply store

All parts available on Ebay except as noted

I have never change out the axle shaft bearings or seals. Never found them bad. Shame on me

Thanks to Gwest for his input on these lists.

2

Hey Rodney,
I’m pulling together the parts to rebuild my differential before I take it apart. The Exploded View/Parts List in the Dana Spicer Transaxle Service Manual that I have shows an O-ring on either side of the intermediate shaft bearing - a large one (#133) on the outside and a small one on the inside (on the intermediate shaft itself - item 10 in the parts list). Do you perchance have an O-ring number or dimensions on that small O-ring?
Much appreciate the help,
Don

3

Due to the fact the bearings used in this area are open these O’rings are not needed. The Caps (freeze plugs) seal these areas.

Rodney

4

Based solely on looking at the referenced drawing (it’s been three years since I was inside this gearbox) it appears to me the o-rings might act as spacers - to locate the bearing from the snap ring on the outer and to prevent side-to-side movement on the intermediate shaft.
As cheap as two small o-rings are, I don’t see a reason to leave them out. I’ll take a closer look when I get the box apart.
Thanks again for the input,
Don

FWIW - the small o-rings are size -015 9/16x11/16 and a buck apiece at my local supplier.

5

I believe O’rings in that area are a throwback to when they used seal bearings without caps. Same as on the input shaft.

Rodney