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Old 04-07-2014, 09:46 PM   #1
Cvans
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Default Installing a G2 differential into a G1

Today I made a 45 mile trip to pick up a G2 for the differential. I'm going to try and do a photo thread on the steps necessary to do this conversion.
This is the donor that followed me home today.
Next is the two differentials setting next to each other, G2 in front and G1 nearest. I tried to line them up by the seams in the gear case. First notice the difference in the clutch springs. The spring in the G1 appears to have fewer coils but the spring diameter is larger.
I was told that the axles and axle housing are interchangeable. If this is the case lining up the clutches should not be much of a problem. Tomorrow I'm going to pull the axles and housings and and check on their compatibility. Seeing as how none of the mounting holes line up I hope things will swap over.
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Old 04-07-2014, 10:06 PM   #2
smokindawg
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Default Re: Installing a G2 differential into a G1

I look forward to seeing your change over as I will be doing the same in my cart as soon as I can find a rear or a donor cart with one.
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Old 04-07-2014, 10:24 PM   #3
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Default Re: Installing a G2 differential into a G1

Smokindawg I can't recommend Craig's list enough. I have had excellent results in locating things with Craig's help. I actually had 2 contacts within 24 hours of posting my needs. Make sure to post a photo of the cart your looking for. The guy that had this one had no idea what model his cart was until he saw my photo.
Good luck with your search.
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Old 04-08-2014, 06:13 AM   #4
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Default Re: Installing a G2 differential into a G1

Thanks. I've been looking on there but hadn't thought about advertising that I was looking for one.

I'll have to get right on that.
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Old 04-08-2014, 07:48 PM   #5
Field6565
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Default Re: Installing a G2 differential into a G1

Great find Chris! Yeah I found my G2 rear end on craigslist....paid $60 for it. It looks like your secondary sheaves on your G1 are extremely worn. That could have been killing your top end speed. I ended up using the G2 secondary clutch with the G1 gold spring on mine. When it's in low gear it feels like it could pull a house down...when it shifts into high gear it really takes off. Good mixture of both low end torque and very fast on the top end.
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Old 04-08-2014, 09:03 PM   #6
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Default Re: Installing a G2 differential into a G1

Hi Field,
You have a good eye. I did take that sheave and put in the lathe and true it up. No more ridges so we will see it works out now. It is on the list of things to replace after I'm sure that everything is going to work. I'm also looking at cutting the two frames and using the G2 front suspension on the G1 but that is a long ways out and I haven't taken any measurements yet. The Honda 400ex shocks for the back came today so those will be getting installed during this project.
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Old 04-08-2014, 09:40 PM   #7
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Default Re: Installing a G2 differential into a G1

Today I swapped the axles and axle housings and they did interchange. Unfortunately the driven pulley is way out of line with the drive pulley. Too far to the left and is hitting the frame. Also the angle of the mounts is off so the driven pulley is too low. The mounting bolts did line up though.
So tomorrow I going to pull the tubes and cut them. One an inch (guessing for now) shorter than the other. Then the flanged pieces will be swapped side for side and welded back together. This should move the differential over enough to line the pulleys back up. This will also allow me to rotate the differential to the correct angle. Getting this right is going to be a challenge for this guy.
Also had to redo the rear engine mount to allow enough clearance for the shift shaft. I was warned about this so once again the advice from the members here came in handy.
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Old 04-09-2014, 06:31 AM   #8
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Default Re: Installing a G2 differential into a G1

Are you putting the diesel engine in this? Or which engine? If it's the stock G1 engine then yes you'll have to mount it in the stock location. If it's a clone, or any other you can just position the engine to line up with the driven clutch. So wasn't sure what you're plan was?

Why not use the whole G2 cart? Is the frame rusted out at the battery tray area? That's what happened to mine. But one of the members here did a pretty good repair, didn't look too bad....of course he is a metal worker LOL.

When I did my swap I used the G2 swing arm and stretched it. I went 8", but I think to make it the same length as the G1 swingarm the difference was only 3 or 4 inches. The G2 swingarm will ease the mounting of the diff/trans. Stretching it was really easy. I had to narrow the mounts a tiny bit, they wouldn't fit easily in the mounting ears, maybe 1/8". The shock mounts will need to be relocated, but that was also easy when it was on the workbench/weld table.
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Old 04-09-2014, 06:44 AM   #9
Tonka329
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Default Re: Installing a G2 differential into a G1

Let me know if you would like to sell any parts off that cart....
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Old 04-09-2014, 10:56 AM   #10
Cvans
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Default Re: Installing a G2 differential into a G1

Yes this Diff. is going in the diesel conversion. The location of the engine is pretty much has to remain as it is in order to fit between the frame rails. Also moving the the engine would leave the driven pulley too close to the frame. By changing the dimensions of the axles and housing and using the original mounts all 4 wheels & tires will stay the same in relation to each other. Hopefully this evening I will have gotten past this.
As far as using the G2, I much prefer the one piece body and easy access to the drive train of the G1.
Tonka, why don't you make up a list of what you need and send me a private message and we can go from there.
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