Good morning I have a 2002 GEM E825 and over the weekend I noticed the passenger side axel boot was split. Does anyone know if the sell a replacement boot?
Yeah… it happens. I’d say you did pretty good getting 23 years out of the ones on your car.
CV’s are a tricky repair. They are a PITA since you need to knock most of the front end apart just getting to them. Once you get them on the bench, you need to strip the axle down and clean it out real good. It is a messy job and takes some special tools to make the job easier.
This also assumes your original Cv’s are still in good shape to use.
Depending on your skill set and talents, this may work for you.
Some people find it easier to order up a complete half shaft assembly and call it a day.
There are quite a few How-To examples over on YouTube Universitiy if you want to see what you are getting yourself into.
Thank you. I’ll check out YouTube University and see what’s involved.
Here is one that shows how to do it on a SxS (fairly close to how it would work on a Gem.
Note that this video shows the outboard CV sliding right off. I believe the Gem uses a spring clip retainer that must be dealt with to remove it from the axle.
From the Service Manual
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Planning Ahead
Since you are doing one boot, you might want to inspect the other side to see if it is going to need it done also.
Again thank you for your help.
so nobody sells a 2-piece replacement CV cover? Are the RPMs on an NEV still too high to risk a little bit of imbalance.
Yea I’m looking into that. When I get to camp (Where the Gem is) I’ll take some measurements so see if a split boot will fit.
I doubt this is an imbalance issue.
- Boot is very close to the center
- At 35mph, quick math shows the boot is spinning about 580 rpm
My thought would be more of an inability to seal issue. What does that look like?
Driving straight is easy on the boot. Take it into a full lock and watch that boot compress and expand as it goes round-round a couple times a second.
I’ve never tried one.
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I ordered a split universal boot. I’ll update this post once I install it. Another question I just installed 6 new batteries now when I turn on headlights at night they are dull. The GEM charged ok and it holds the charge as expected with new batteries. I’m thinking I disturbed a ground wire somewhere. Does anyone have a path to the electrical diagrams for 2002.
Plus when I do turn lights on they are definitely draining the system. Wipers move real slow and if I step on the gas lights get even dimmer. Not sure where to start looking
Its been a few years but I purchased my boots from NEV. I found the job to be very easy but I have automotive experience. Little messy but easy. I guess it all depends on knowledge and skill level. I think the tricky part for a first timer would probably be the C clips. I would recommend doing both since you already have the shaft out. I wouldn’t recommend a split boot. Short cuts usually result in a poor repair that has to be redone the right way in the near future. Cant tell you how many times I tried a short cut only to re do the job the correct way shortly there after.
when I do turn lights on they are definitely draining the system. Wipers move real slow and if I step on the gas lights get even dimmer.
The drive/throttle is totally a different system from the 12v accessories. They don’t even share a common ground.
It sounds like someone removed the DC converter and wired the accessories direct off one battery.
When the key is off, do the lights and accessories still work?
I am the original owner so I know there’s been modifications and no when the key is off no accessories work. Like I was saying everything was fine until I changed the batteries that’s why I was thinking maybe I disturbed a ground wire. I looked around and found 3 ground wires under the hood attached to the frame and a 4 pin connector that is part of the ground circuit going to the headlights that felt kinda warm.the car is at camp so when I get back there I’ll take a pic of the connector
You shouldn’t need permission to clean any suspect connections. Especially since it may have felt kinda warm.
Yes, all 12v accessories use frame(chassis) ground for -12v.
If you have doubts, you should meter the accessory supply to see what you are running. +12v is supplied by the DC Converter. It is regulated and steps down your main pack voltage. If you see your voltage dip when throttle is applied, then you should look for something miswired or possibly a bad converter.
It may be total coincidence that it is having issues since your battery swap. Inspect all the batteries to make sure there are no other wires coming off any of the batteries other than the main large cables.
ok so now the dumb questions… Where is the DC converter?Is it under the dash? Would I be measuring off the Converter to see if it dips when throttle is applied.
I read up on the converter and understand it’s function and it’s location. When I get to camp I’ll check it out and get back to this post. I also see there was a recall on this for 2002
cars. Don’t remember getting a notice but again I’ll check it out
Wonder if someone can explain this to me. Im still trying to figure out the headlight issue.First off electric is not my strong suit so be gentle. When I turn headlights on I’m getting 9.7v to lights. When I step on gas it drops to 8.2v. And the 2 wires going to lights when I check them to ground they both Ohm out plus there’s also a 4 pin connector in that loop and all those wires ohm out to ground also. I tried with connector plugged in and unplugged. That doesn’t make sense to me. What am I missing? BTW sometimes lights do work with the key in the off position. Thank you for any feedback
What do you think I have been trying to do here? I offer suggestions but you wave them off and ignore them.
and no, when the key is off no accessories work.
Then you give incorrect info such as this?
Seriously… I am wasting my time even responding at this very moment.
For starters I wasn’t aware of the ignition part until last night. I’m not ignoring your response I’m just trying to understand why with the electrical comments. I’m in the process of trying to get a DC converter since there was a recall on this awhile ago. Thanks for the help
So “Assy Required” just went back a reread all the post and I see where you explained the 12v supply to all the accessories and looking for something miss wired. I thank you for that. I going forward with trying to get all the recall parts for the DC converter. I wasn’t ignoring any of your post I just over think things sometimes. I’ll update this once I can figure out this recall..