Lists of Alternative and Superseded Parts

There are many component parts that, until recently, were only available from GEM as a complete assembly. To name a few, brake calipers, the steering rack, suspension A arms, wheels, drum hubs, the throttle, and others. I will add specific sources as they are located. GEM does periodically add component parts, so if you are using an older manual, call the GEM parts department at the factory before ordering from the dealer. The best example is the transaxle input shafts, which are now available. I wonder how many of us have spent $1,000 on a new transaxle because the input splines were slipping?. The brake calipers are about $250 each and no components are available from GEM or any known EV parts source. I have found a source for rubber caliper seals. A steering rack is about $450 and only the outer tie rods and boots are available, these were added by GEM about a year ago. For the inner tie rod, I have found a VW rabbit part that matches the steering rack exactly, but needs a M14X1.5 sleeve so that the male inner tie rod can fit the also male outer tie rod. Steering rack boots frequently tear and fall apart after a few years. These are now available from GEM. However, there is a less expensive Polaris Ranger ATV rack boot that is an exact fit for both sides. The rubber bushings on the front A arms of 2005+ GEMS are now available. Previously, I made my own bronze bushings on my lathe and adjust the preload by butting two nuts together. These are in the size 1.435" round by 1.510" long drilled to 10 MM. This procedure is detailed in another of my posts. Another member has successfully used nylon bushings on their A arms. Wheel bearings for 4 lug drum hub assemblies are not sold by GEM, but are easy to find from any bearing source. Two are needed per wheel and must be pressed in, which is not expensive. The 4 lug drum hub assembly new costs about $350. The 5 lug drum brake used on the elxd truck uses parts available from any auto parts store. The throttle for pre-2005 GEM is actually an arc welder foot control made by Linemaster Switch. This company is happy to provide repair parts. If your throttle sticks and the spring is broken, a spare is only a few dollars. The spring is now available from GEM at a much higher price. Lastly is the key switch which is available from GEM, but at $150, my money goes to a NAPA part that is only $14. Only the terminals need to be changed to make it work and key blanks are readily available. Forget about trying to find the original Italian made keys. I plan to create as complete as possible a list of alternative GEM parts. I continue to search for wheel cylinder seals, master cylinder seals, and others.

List of Alternative Parts Sources

This list is the result of exhaustive efforts to find many items GEM does not sell at the component level. Over the years, compiling this list has saved our members thousands of dollars and weeks of down time. Some of these parts are represented solely because of time savings in shipping. Since the Polaris takeover, GEM dealers no longer drop ship parts. I have examined and tested most, but not all, of the below parts. Much thanks to the various other members who have contributed ideas to this list, some of which involved hours of research and countless phone calls. If anyone has more ideas, please allow me to add them here. Any questions on obtaining and fitting the below parts can be answered by calling me at 443-802-1140.

pre-2005 throttle return spring: 975-W9 Linemaster Switch Corporation (exact OEM part, about $2)
also available from GEM as part # 0610-00796

pre-2005 throttle 5KΩ pot: LSC-804-4 Linemaster Switch Corporation (exact OEM part)

pre-2005 throttle micro switch: 975-X11 Linemaster Switch Corporation (exact OEM part)

pre-2005 throttle assembly (complete): 09ASAC-5K Linemaster Switch Corporation (exact OEM part)

large oval brake lamp assembly: 50-60202R3 NAPA Auto Parts (made by Truck-Lite)

large oval LED brake lamp assembly: Pilot Travel Center (or any truck stop) $16.99

gasket for brake lamp: 60700 NAPA Auto Parts (made by Truck-Lite)

headlamp halogen capsule: H3 (12 volt, 35 watt) this is actually a fog lamp bulb

headlamp assembly: 12084333 Electrick Motorsports

key switch: KS6040 or KS6115 NAPA Auto Parts (about $14)

latch for front hood: Southco C7-10 “small over center draw latch with concealed keeper” (OEM order from Amazon or boating supply. These fit many Sea Ray power boats.)

120 volt inlet for charging plug: 150BBIW Marinco Marine (order from any boat dealer)

12 volt outlet for accessory: 12VRCW Marinco Marine (order from any boat dealer)

Dekka 12 volt GEL battery: 8272 NAPA Auto Parts (OEM battery, but with NAPA label, over $200)

Zivan NG1 16 AMP charger fuse (Weber type): Mersen 16035-G, order from Fusecoinc.com

Zivan NG1 16 AMP charger fuse (SIBA type): Wickman 2312160, order from Fusecoinc.com

main fuse in battery circuit for 1998-2004 72 volt with 400 amp: ANE-400A, order from Kelly Controls

main fuse in battery circuit for 2005 and newer with 250 amp: ANE-250A, order from Kelly Controls

18" wiper blade: 60-018-1 NAPA Auto Parts (2" longer than OEM, works great)

Replacement wiper motor: 34000 Marinco (order from any boat dealer)

Wiper arm for above wiper motor: 33010A Marinco (order from any boat dealer)

12" tire size 5.3X12: CL519077 Carlisle (works great, quality US made DOT trailer tire)

steering rack boot: 5412013 Polaris (exact fit for both sides, order from motorcycle/ATV dealer) 5412013 is a Polaris Ranger ATV part, not a factory GEM part. These can be ordered online through Bike Bandit.

steering rack boot: 269-1664 NAPA (not an exact fit, but works)

inner CV axle boot: GEM-HSBK, order from NEV accessories (lowest price)
alternate number: 602951 EZ-GO (exact fit both sides, order from golf car dealer)

inner tie rod: 2695088 NAPA Auto Parts (VW Rabbit/Jetta part, need M14/1.5 threaded sleeve to fit) (this has only been tested on 2004 and older GEM) This is a work around to avoid replacing the whole rack because GEM doesn’t sell the inner tie rod.

10mm copper washers for 4 lug drum brake: 97725A200 McMaster-Carr (25 count)

wheel bearings 4 lug drum brake only: trade size 6006 double sealed, 6661K89
Mcmaster-Carr (two per wheel)

12mm standard length studs for four lug drum brake: 641-1064 NAPA

12mm extended length studs for four lug drum brake: 641-4223 NAPA

rear wheel bearing / hub for 5 lug drum brake (elxd truck): BR930173 NAPA

rear wheel stud for 5 lug drum brake (elxd truck): 6411058 NAPA

wheel seal for 2005 and newer front disk brake: 15819 NAPA Auto Parts (two per wheel)
alternate number: GEM-FWB-SEAL NEV Accessories (two per wheel)

wheel bearing for 2005 and newer 4 lug front disk brake: GEM-FW-BEAR NEV Accessories

caliper piston seals for 2005 and newer 4 lug front disk brake: 4061T168 Mcmaster-Carr (100 count is about $11, 2 per caliper)

caliper small internal o-rings for 2005 and newer 4 lug disk brake: 9452K18 Mcmaster-Carr (100 count, 2 per caliper)

plastic cap for master cylinder: 6751204 (cap) and 6751219 (rubber gasket) NAPA Auto Parts

E-clip for brake cables (two per cable): 98408A138 Mcmaster-Carr (10 count, stainless steel)

brake drum 4 lug (all years and locations): NEV Accessories $45

brake drum 5 lug (elxd truck): 4401811 NAPA

brake shoes 4 lug drum (all locations): NEV Accessories (set of four shoes)

brake pads 4 lug front 2005 and newer: EBC FA271 (2 pads, order from motorcycle dealer)
alternate number: Magnum Braking AT2711 (2 pads, order from motorcycle dealer)
alternate number: NEV accessories GEM-BK-PAD (2 pads, discount for quantity purchase)

brake shoes 5 lug drum (elxd truck): UP10810 NAPA (set of four shoes)

front wheel cylinder for 4 lug drum: NEV Accessories

rear wheel cylinder for 4 lug drum: NEV Accessories

rear wheel cylinder for 5 lug drum (elxd truck): 370176 NAPA

brake spring kit for 5 lug drum (elxd truck): 3301 NAPA

parking brake self adjust springs (elxd truck): 80997 NAPA

parking brake self adjust screw left (elxd truck): 81542 NAPA

parking brake self adjust screw right (elxd truck): 81543 NAPA

front disc brake conversion kit for pre 2005 GEM: NEV Accessories

parking brake cables for 4 lug long wheelbase: GEM-BR CABLE L sold by NEV Accessories, these are the correct length for a 4 passenger GEM. Less expensive than dealer and fits better.

o-ring for transaxle input bearing: 3/32" X 1 13/16" X 2", 9452K148 Mcmaster-Carr

input shaft seal for newer GEMs and those that have had the input shaft replaced: 26761G01 E-Z-GO (order from any golf car dealer)

transaxle input bearing (large): trade size 6005 double sealed, 6661K88 Mcmaster-Carr

transaxle input bearing (small): trade size 6203 open, 5972K104 Mcmaster-Carr

2004 and older motor bearing at commutator end: trade size 6203 double sealed, 6661K104 Mcmaster-Carr

2005 and newer motor bearing at commutator end: trade size 6204 double sealed, 6661K105 Mcmaster-Carr

motor brushes: 625A675AA4 Arrowhead Electric (located in California, 4 per motor) this has only been tested on 2005 model year (2004 and prior are different)

motor stud insulator kit: 1017947 Club Car (order from golf car dealer) should fit all GE motor

motor speed sensor: 1022656-01 Club Car (order from golf car dealer)

motor speed sensor magnet: 1022657-01 Club Car (order from golf car dealer)

alternate number for magnet: JU2-H185B-00 Yamaha (order from golf car dealer)

rubber bumper for motor to input shaft: 1022352-01 Club Car (order from golf car dealer)

72VDC/12VDC converter (direct fit, OEM equivalent sealed unit): 22130, rev A SPS Electronics

auxiliary 72VDC/12VDC converter: 350 watt converter, order from Locoverter.com (29 amp output, made for 72VDC locomotives)

Nylon Shock absorber bushings - Old Houseboater this Forum

Daniel

6 Likes

Great information, thanks for the effort. One of my headlights (02 model)burned out, and I don’t see a bulb listed in the parts manual I have. I can probably find it, bit it may be easier to find a headlight at a parts store.

[QUOTE=GEMmechanic;8731]There are many component parts that, until recently, were only available from GEM as a complete assembly. To name a few, brake calipers, the steering rack, suspension A arms, wheels, drum hubs, the throttle, and others. I will add specific sources as they are located. GEM does periodically add component parts, so if you are using an older manual, call the GEM parts department at the factory before ordering from the dealer. The best example is the transaxle input shafts, which are now available. I wonder how many of us have spent $700 on a new transaxle because the input splines were slipping?. The brake calipers are about $250 each and no components are available from GEM or any known EV parts source. I have found a source for rubber caliper seals. A steering rack is about $330 and only the outer tie rods and boots are available, these were added by GEM about a year ago. For inner tie rod, I have found a VW rabbit part that matches the steering rack exactly, but needs a M14X1.5 sleeve so that the male inner tie rod can fit the also male outer tie rod. Steering rack boots frequently tear and fall apart after a few years. These are now available from GEM. However, there is a less expensive Polaris Ranger ATV rack boot that is an exact fit for both sides. The rubber bushings on the front A arms of 2005+ GEMS wear out rather quickly, and are not sold separately. Each of the 4 A arms cost $220, so I made my own bronze bushings on my lathe and adjust the preload by butting two nuts together. If one looked hard enough, they could find bushings in the size 1.435" round by 1.510" long drilled to 10 MM. Wheel bearings for drum hub assemblies are not sold by GEM, but are easy to find from any bearing source. Two are needed per wheel and must be pressed in, which is not expensive. The drum hub assembly new costs about $350. The throttle for pre-2005 GEM is actually a welder foot control made by Linemaster Switch. This company is happy to provide repair parts. If your throttle sticks and the spring is broken, a spare is only a few dollars. The spring is now available from GEM at a much higher price. Lastly is the key switch which is available from GEM, but at $150, my money goes to a NAPA part that is only $14. Only the terminals need to be changed to make it work. I plan to create as complete as possible a list of alternative GEM parts. I continue to search for wheel cylinder seals, master cylinder seals, and others.

List of Alternative Parts Sources

This list is the result of exhaustive efforts to find many items GEM does not sell at the component level. Over the years, compiling this list has saved my employer more than a thousand dollars and weeks of down time. I have examined and tested each of the below parts. If anyone has more ideas, please allow me to add them here. Any questions on fitting the below parts can be answered by calling me at 443-802-1140.

pre-2005 throttle return spring: 975-W9 Linemaster Switch Corporation (exact OEM part, about $2)
also available from GEM as part # 0610-00796

pre-2005 throttle 5KΩ pot: LSC-804-4 Linemaster Switch Corporation (exact OEM part)

pre-2005 throttle micro switch: 975-X11 Linemaster Switch Corporation (exact OEM part)

pre-2005 throttle assembly (complete): 09ASAC-5K Linemaster Switch Corporation (exact OEM part)

brake lamp assembly: 50-60202R3 NAPA Auto Parts (made by Truck-Lite)

gasket for brake lamp: 60700 NAPA Auto Parts (made by Truck-Lite)

key switch: KS6040 NAPA Auto Parts (about $14)

Dekka 12 volt GEL battery: 8272 NAPA Auto Parts (OEM battery, but with NAPA label, over $200)

18" wiper blade: 60-018-1 NAPA Auto Parts (2" longer than OEM, works great)

12" tire size 5.3X12: CL519077 Carlisle (works great, quality US made DOT trailer tire)

steering rack boot: 5412013 Polaris (exact fit for both sides, order from motorcycle/ATV dealer)
also available from GEM as part # 0612-00326

inner tie rod: 2695088 NAPA Auto Parts (VW Rabbit/Jetta part, need M14/1.5 threaded sleeve to fit)

wheel bearings drum brake only: trade size 6006 double sealed, 6661K89 Mcmaster-Carr (two per wheel)

wheel seal for disk brake only: 15819 NAPA Auto Parts (two per wheel)

Caliper piston seals for disk brake: 4061T168 Mcmaster-Carr (100 count is about $11, 2 per caliper)

pre-2005 brake hoses from tee to rear drums: 813-1263 NAPA Auto Parts (metal, about $4 per side)

E-clip for brake cables at rear drums: 98408A138 Mcmaster-Carr (10 count, stainless steel)

transaxle input bearing: trade size 6005 double sealed, 6661K88 Mcmaster-Carr

motor bearing at commutator end: trade size 6204 double sealed, 6661K105 Mcmaster-Carr

motor brushes: 625A675AA4 Arrowhead Electric (located in California, 4 per motor)

axillary 72VDC/12VDC converter: PST-DC/7212-9 72/12 Powerstream, about $150 (compact 9 amp output, made for 72VDC locomotives)

Daniel[/QUOTE]

The headlamp capsule is trade number H3 35 watt and is readily available after market at any auto parts store. The GEM headlamp is a halogen fog lamp bulb. Just remove the lamp and take it in. Any NAPA or similar place can match it up for you. Have gotten several of these lamps there in the past. Install it with a tissue. Do not allow anything to touch the lamp. They are sensitive to moisture.

Daniel

1 Like

Thanks, I figured that one out after looking at it closely. Its an H3 -12V35W bulb - it has a primary wire attached. At 3-4 bucks, its way better than the 50most places want for the light assembly. Unfortunately, I don’t see any of the dealers offering the headlight bulb separately.

[QUOTE=GEMmechanic;9621]The headlamp capsule is readily available after market at any auto parts store. The GEM headlamp is a halogen fog lamp bulb. Just remove the lamp and take it in. Any NAPA or similar place can match it up for you. Have gotten several of these lamps there in the past. Install it with a tissue. Do not allow anything to touch the lamp. They are sensitive to moisture. I will enter the number in the list soon as I get back to the US.

Daniel[/QUOTE]

The lacking of GEM component repair parts is absurd. This problem used to be much worse. I’ve been told that, originally, even the brake pads weren’t sold separately. So, every time one of our four GEMs broke, I looked for alternative parts. Soon I had a long list and decided to share it. Caliper o rings, wheel bearings, transmission seals, rack boots, are just a few of the things we take for granted in the auto parts business. At one time, none of these parts where available from GEM as component parts. If your using an old parts manual, my list is especially helpful. Because the factory, over the years, has added many new parts that used to be sold only as an assembly. The rack and pinion boots are a good example. How many people over the years have bought a whole new headlamp rather than just a bulb? This really hurts people who must use the dealer, because a customer usually isn’t allowed to bring their own parts. Kind of like bringing my own steak to the restaurant. Below are the top parts I would like to see GEM offer as components:

A arm and suspension bushings (these were added recently)
motor brush kit (available after market)
trans axle seal and o ring kit (components available after market)
drum brake hardware kit (available aftermarket for elxd truck with 5 lug)
master cylinder seal kit (helpful, but we’ve never had one fail yet)

I wonder if anyone from GEM reads these forums? GEM’s parts and service departments had improved in recent years until the Polaris takeover. I guess we just live in a throw away society.

Daniel

I’m sure this won’t be useful to anyone, but who knows. The OEM front turn signals appear to to be Peterson 152 Series clearance & side marker Lights. Peterson also make two LED alternatives that would fit in the same space, but may require drilling new mounting holes. These are the 203 Series or the 153 Series.

Also, the tail light is a Truck-lite model 548. You have the NAPA number, just thought the OEM model number might be useful as well.

I finally found high quality LED direct-replacements for the turn signals at Super Bright LEDs.

For the past year, I have been answering tech questions on here while deployed to Iraq. I plan to update the big parts list in the next few weeks after getting home. I will add the Zivan charger fuses, the after market DC/DC converter, and a complete listing of LED lighting. I will convert our 2005 GEM to all LED and report the results. Everything will come from NAPA to eliminate shipping cost. LED is especially useful on electric vehicles that see a lot of operation at night because of reduced amperage draw. I will also evaluate the turn signal flasher compatibility. Many flasher circuits get confused by the very low amp draw.

Daniel

[QUOTE=GEMmechanic;9808]For the past year, I have been answering tech questions on here while deployed to Iraq. I plan to update the big parts list in the next few weeks after getting home. I will add the Zivan charger fuses, the after market DC/DC converter, and a complete listing of LED lighting. I will convert our 2005 GEM to all LED and report the results. Everything will come from NAPA to eliminate shipping cost. LED is especially useful on electric vehicles that see a lot of operation at night because of reduced amperage draw. I will also evaluate the turn signal flasher compatibility. Many flasher circuits get confused by the very low amp draw.

Daniel[/QUOTE]
Glad to hear you’re coming back safe and sound. The nearest NAPA is 30 miles away, does NAPA ship as well?

Finding an LED version of the Trucklite taillights are going to be the problem. The only current solution is the use LED replacement bulbs in the current incandescent housing. This will probably work fine, but it’s still not the equivalent of a proper LED S/T/T turn light.

PS: If you find an LED headlight that will work, please let me know!

The oval LED tailights are easy to find. The $28 ones from NAPA are bright enough. The H3 35watt 12 VDC lamp is available in LED. There is no guarantee that these will be bright enough. They can be found on Ebay, Amazon and several of the online lighting dealers. The H3 is actually a fog lamp / daytime running lamp. LED dealers are reluctant to tell you what the halogen wattage equivalent of their products are. So, you won’t know how bright they will be until you install. Adding to this, the H3 is sold in various wattages. These should easily outlast the GEM. I am encouraging my employer to begin switching over to LED lighting in our buildings. The military uses LED headlamps because nearby explosions will not easily break them.

Daniel

Those LED replacement bulbs are probably not going to work very well. The main problem with them is that the reflector is designed to reflect the light emitted from a point source, i.e. a filament. Much of the light from the LED replacement bulbs will be scattered in the wrong direction. This is a double hit, as the LED bulb in all likelihood will not even match the lumen output of the stock halogen bulb to start with. We need to find a LED driving light designed from the beginning to use LED as the light source. I have seen LED driving light on the market already, but just not in the same form-factor used on the GEM. Until then, I’ll personally stick with the stock bulbs.

I’m looking into retrofitting HID projectors into the GEM. The entire lighting housing will have to be removed, and clear lenses will have to be made that protrude a half inch or so out of the current holes in the hood… The HID projectors can then be mounted behind the new lenses. This will use the same 35 watts of the current headlights, but will at least provide much better road visibility. I’ve got the whole thing figured out in my mind, but making the lenses still has me stumped on the project.

BTW, you might want to add this ebay seller to your parts list. He sells 6 pairs of battery tie down bolt kits for $10.23 with shipping. He sells the 8", 10" and 12" lengths. Those longer ones can be hard to find. If you email him after ordering, I believe he is willing to mix sizes in an order. He says he has thousands, so I don’t think he will be running out any time soon.

All of the turn and tail lights are available in LED at any truck stop. The prices are very good and, of course, there is no shipping. Remember when installing that, by nature, LEDs have polarity and do not work if connected backward. If a lamp won’t work, try reversing the leads,

Daniel

OK, not the hardest thing to track down, but I had some problem finding it when I didn’t know exactly what it was called.

The OEM charger inlet is a Marinco model 150BBI. They also have a model 150BBIW that’s white. Nice option to match the white of the GEM. About $16 from Amazon.

GEM also uses the Marinco model 12VRC for the OEM 12 volt accessory socket. Again, a white version is available as the 12VRCW. About $9 from Amazon.

Anyone needing a new key for your GEM, you can order a pair (2 keys) from Midwest Security Products for $15. Just read them the code on your existing key; their number is 800-767-6894. Write down the number on your key NOW in case you need a replacement later!

The stock OEM main disconnect switch in the GEM is only rated for 20 Amps continuous at 12 volts, and only rated at 125 Amps for 15 seconds! They are a Cole-Hersee model 2484. Even though they seem to work fine, replacing with a better model could be a smart move.

This page here shows the other models available. There are three choices to pick from that are rated at a much better 175 A continuous and 1000 Amp intermittent, and they all look identical to the stock switch.

Model 2484-09 is unsealed with copper contacts, like the OEM model.

Model 2484-06 features an “O” ring in bushing, gasket-sealed terminal insulator, and case to bushing seal.

Model 2484-A is unsealed, but features improved silver laminated contacts.

This company here sells any of these models for under $40. I’d think 2484-A is the best-buy, being the cheapest and also having superior silver contacts.

headlight cant seem to find 12084333 electrick motorsports thanks anthony

The link for GEM headlamp:

Head lamp

If you just need the bulb, it is a H3 fog lamp bulb available at any auto parts store.

Daniel

no the whole light fixture thanks

I’m sure this won’t be useful to anyone

[QUOTE=tuananhpl1;15193]I’m sure this won’t be useful to anyone[/QUOTE]

Could you be more specific in your post? Not sure what you are trying to say there.

Daniel

thanks for this great info!!