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Old 12-29-2023, 04:16 PM   #1
Greenbeanz
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Question Ez-Go Workhorse ST480 Wheel Cylinder

Trying to replace or rebuild the wheel cylinders on my Workhorse ST480.
a complete wheel cylinder found under the ez-go and Cushman part #’s ranges from $130-$400 for one. I am now trying to find a rebuild kit instead, but hitting a wall with cross referencing any numbers over. The cylinder body has a cast # of 4170128; The spring cups are 7/8” with a part # of 3023; The pistons (obviously 7/8”) have a part # of 27799; The dust boots have a part # of 21963; the return spring is approx. 2 & 1/16 inches long. The cylinder body w/o the dust boots on is 2 & 5/16 inches; dust boot has a diameter of 1 & 1/8"
***Initially I found a wheel cylinder (part# 4255) that said it was compatible with the Workhorse ST480 and the Cushman Commander, so I ordered them and it’s about 1 inch bigger, the bore size is smaller (3/4”) and the inlet and bleeder are swip-swapped. So for anyone thats in the same boat as I am, DON’T purchase the #4255, it does not match up!
Attached Images
File Type: jpg wheel cylinder breakdown.jpg (209.0 KB, 0 views)
File Type: jpg cylinder comparison.jpg (216.0 KB, 0 views)
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Old 12-29-2023, 08:24 PM   #2
Leon willis
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

You don’t need no brakes on your ezgo,but brake shops could probably figure it out and find out parts to rebuild it and be able to rebuild it
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Old 12-30-2023, 01:49 AM   #3
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

It took a lot of time to track down wheel cylinders for my 1998 Cushman Hawk.

My original wheel cylinders were 7/8” diameter with a main cylinder body width of 2.285”, which is pretty close to the 2-5/16” width you show. The round mounting profile looks similar to yours as well (see my photos below). The Cushman part number for this is 700472 based on my owner’s manual, but I am not sure if that is accurate for my 7/8” cylinders.

I was not able to find anything to match the 7/8” piston diameter but was able to find something “similar” in a Ύ” piston diameter. I tracked these down at a reasonably well-known golf cart parts supplier (who are not a Site Sponsors of BGW, hence will remain nameless) for about $50 per wheel cylinder in June of 2021.

When I received the wheel cylinders, I noted they were manufactured by Centric Parts / Stop Tech with part number 134.04000. Looking up these wheel cylinders online, I found that they were original equipment on the 1969 – 1973 Fiat 850 and the 1971 – 1979 Fiat 128. I also cross referenced these wheel cylinders to a Dorman W37347. At the time, I priced these part numbers at a nationally know internet automotive parts supplier for $7 to $8 each.

Although these Ύ” wheel cylinders were an exact bolt on for my old cylinders, the overall mounting width at the slotted link ends (brake pad slots) was wider than the 7/8” OEM wheel cylinders. I ended up grinding down my brake pad frames a little bit at a time until the brake drums would comfortably fit over the assembled brake pads (see photos for clarity).

Note that a Ύ” wheel cylinder has a piston cross section area of 0.441 in2. A 7/8” wheel cylinder has a piston cross section area of 0.601 in2.

The larger cross-sectional area of the 7/8” wheel cylinders provides 36% more stopping force than the Ύ” wheel cylinders. Or another way of looking at it is that that it would take you 68 lbs of brake pedal force with the Ύ” wheel cylinders to generate the same stopping force as 50 lbs of brake pedal force with the 7/8” wheel cylinders. In short, I find it takes noticeably more brake pedal force to stop with the Ύ” wheel cylinders. It is not a showstopper (no pun intended) but it is noticeable and drivers with less leg strength may have trouble with braking in higher speed situations.

My recommendation is to find the correct diameter wheel cylinders for your cart if you can.

I hope this helps you in tracking down some wheel cylinders for your cart. Let us know how you make out.

Regards, 3CW
Attached Images
File Type: jpg 1 Original Cylinder.jpg (325.8 KB, 0 views)
File Type: jpg 2 New vs Old Cylinder.jpg (184.7 KB, 0 views)
File Type: jpg 3 Mounting Plate.jpg (288.9 KB, 0 views)
File Type: jpg 4 Mounted Brakes.jpg (444.7 KB, 0 views)
File Type: jpg 5 Trimmed Pad Mount.jpg (356.7 KB, 0 views)
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Old 12-31-2023, 02:04 AM   #4
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

Here is a link to the Centric Wheel Cylinder 134.04000 which is a 3/4" bore diameter.

https://www.centricparts.com/drum-br...linder-6822428

I am hoping to find a similar mounting in a 7/8" bore diameter to restore my full braking capacity. I will try to contact Centric technical support to see if they can assist.
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Old 01-01-2024, 02:06 PM   #5
Greenbeanz
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

THANK YOU very much on your detailed response with this same situation. I will look into this a little more, and eventually post what my end result was, in hopes to help someone else out on down the road with this same issue.
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Old 01-01-2024, 02:09 PM   #6
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

I’ll be interested to hear if you find anything more helpful out!
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Old 01-02-2024, 02:06 AM   #7
ThreeCW
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

Here is a 7/8" wheel cylinder that may be close to what you require.
I have emailed Dorman and requested a dimensional drawing to see if will be a fit for my cart. I'll post the drawing when they get back to me.
Attached Images
File Type: jpg W37677-1.JPG (32.0 KB, 0 views)
File Type: jpg W37677-2.JPG (35.3 KB, 0 views)
File Type: jpg W37677-007.jpg (46.8 KB, 0 views)
File Type: jpg W37677-006.jpg (53.0 KB, 0 views)
File Type: jpg W37677-004.jpg (46.8 KB, 0 views)
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Old 01-03-2024, 12:29 AM   #8
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

I received a response from Dorman about 6 hours after sending my enquiry … pretty efficient service from their technical department.

Find attached the dimensional diagram for the Dorman 7/8” bore W37677 wheel cylinder. The end-to-end steel body length of the 7/8” Dorman wheel cylinder is 2.756” (70 mm) which is about 1/2 inch longer than both my OEM 7/8” wheel cylinder (2.280”) and my aftermarket 3/4” wheel cylinder (2.228”).

My aftermarket 3/4” wheel cylinder with both pistons fully compressed is 2.485” from slotted piston end to slotted piston end. This compares to the 2.756” (70 mm) body length of the proposed Dorman W37677 … which mean the W37677 is too long, and I will have to find a shorter wheel cylinder that meets my dimensional requirements.

I will do some further digging with Dorman and will let you know my findings.
Attached Images
File Type: jpg W37667 Dimension Diagram.jpg (37.9 KB, 0 views)
File Type: jpg AM Fully Compressed.jpg (212.4 KB, 0 views)
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Old 05-11-2024, 08:28 AM   #9
Brooksdodd123
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Exclamation Re: Ez-Go Workhorse ST480 Wheel Cylinder

Did you figure out what to order ? I’m having the exact issue on my st 480 same part number. Mine are honestly past rebuilding
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Old 05-11-2024, 11:39 PM   #10
ThreeCW
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Default Re: Ez-Go Workhorse ST480 Wheel Cylinder

I was unable to find a 7/8" wheel cylinder to match my OEM Cushman parts. That's not to say that one does not exist, just that I was not able to find one from conventional manufacturers.

I continue to use 3/4" replacement wheel cylinders, which resulted in higher brake pedal force than with the original 7/8" wheel cylinders (as I outlined in my post above).

Let me know if your can find a suitably sized 7/8" wheel cylinder for your ST480 Workhorse.
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