I think I broke it, AC Motor on 05 GEM e4

GEM Forum
1

I had great luck with the help of @lnwo,@AssyRequired , @LithiumGods and @Old_Houseboater getting my motor swapped with an AC kit and lithium setup.

However, this week I was headed down the road and when I went over a bump an intense grinding noise started coming from the motor area and the vehicle no longer would move under power. Even with the power off there was a pretty intense grinding noise just trying to free roll back and forth.

I was able to get to a safe spot pretty quick and tonight was able to pull the motor. I can’t remember if these two blobs of blue things are supposed to be there and it looks like the teeth on both sides are pretty worn. I am guessing this is/was my issue, And going over the bump finally sent it over the edge.

I’m not sure if this is something that’s easily replaceable or if there’s something obvious that it looks like I’m missing. The NEV does free roll without any noises. I also forgot how heavy this AC motor was :joy:.

Any ideas on if this is something that can be repaired? Or do I need to get a motor shop involved?

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2

Wow! This has been eating itself for quite a while. That spline is sooo dry. Has this been making any unusual noise or vibration? How long has this setup been running? Was the motor not installed straight or perhaps coming loose?

That motor is going to need a new coupler(not an easy thing to do). Special tools are going to be needed. Yes, that means a special motor shop.

Your gearbox is also going to need a new input shaft and a new seal.

Those wads of epoxy are there to balance the rotating assembly. Leave them alone.

3

Thanks @AssyRequired for the super fast response. I too was surprised at how dry it was. I had installed this setup back in 2021 and used I believe Honda type grease on it when put together. Clearly it was toast.

I had noticed some noise when letting off the accelerator before regen would kick in, but it didn’t seem too loud or out of place. Apparently I was wrong. When j removed it tonight, nothing seemed loose and all the bolts seemed quite snug that were holding the two together.

I reached out to @Old_Houseboater to see if this is something he could help with. I am based in Kissimmee, FL.

Now to read how to take the gearbox off. If I can transport just the motor and the gearbox, or ship them, it’s doable rather than me having to figure out how to tow the NEV somewhere.