Transmission Shifter

[Sdean1982]

My 2000 Club Cart starts and will run, but it will pop out of gear and doesn't go into gear easily. Any solutions? New cable?

[golfcartg]

From what you've described, there could be a few potential reasons why it's popping out of gear and having trouble shifting smoothly. One possibility is that the shift cables might just need a bit of adjustment. Sometimes even a small tweak to the cable's alignment and tension can make a big difference in how smoothly the gears engage.

To start troubleshooting, I'd recommend trying a simple test. You can disconnect the shift cables from the lever on the transmission and manually shift it into forward gear. If the cart drives smoothly and the lever stays put, it's likely that the issue lies with the cable itself. This would be a good sign because it means the transmission internals might be okay. However, if the problem persists even after adjusting the cable, it's possible that there's something going on inside the transmission. This could be caused by worn input shaft bearings or even a faulty shift fork. In that case, it might be necessary to open up the transmission for a closer look.

Over adjusting the cables could serve as a quick fix. Some people report needing to "hold" the shifter in place to keep it in gear. By tweaking the cable alignment and tension, you can simulate holding the shift lever in place and create more pressure on the transmission gear, helping it stay in gear more reliably without physically holding it. It's like fine tuning to find that sweet spot where everything aligns just right. If you reach a point where adjustments don't seem to do the trick, we might need to consider pulling out the rear end for a more thorough internal inspection. I know this sounds like a big task, but at that point it's the best way to pinpoint the exact issue and get it fixed properly.

I'm including the diagrams which show the shift linkage, transmission mounted shift lever and internal gears for reference. Let me know if you have any questions!

[Sdean1982]

Yea, still pops out of gear and grinds. Now the little shift lever snapped when I was messing with it. Is there anyone that sells aftermarket transmissions? Not having a lot of luck finding any. That or just finding a used one and rebuilding it.

[Michael Eddie]

It seems like the issue with your transmission is likely internal, especially considering the symptoms. To tackle this as cheaply as possible, your best bet is to start by removing the entire rear assembly from your cart. Once you've done that, load it onto your trailer or truck for transportation. Next, it's time to start scouting for repair options.

With the differential assembly in tow and rebuild book in hand, you'll want to drive to various repair shops, transmission specialists, and even lawnmower repair shops. Look for places that offer competitive prices and have skilled technicians who can accurately diagnose and repair the issue. Find a knowledgeable professional that's willing to take on the job, because reassembling the transmission can be quite tricky. To guide the repair shop through the repair process, I recommend printing out the attached rebuild book and bringing it with you for reference.

As far as replacement parts go, there is no such thing as an aftermarket transmission. The curing process is a critical step in the manufacturing of gears and transmission parts significantly impacting their quality and performance. During curing, materials undergo controlled heating and cooling cycles to enhance their mechanical properties, resulting in components with improved strength, hardness, and resistance to wear and fatigue. However, this process is labor intensive and requires specialized equipment and expertise, contributing to higher production costs.

Once you've identified the necessary part for your transmission repair with the help of a pro, purchase it directly from the dealer and be done with it forever. I attached the rebuild book below:

Club Car DS 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07 (Gas) Rear Axle Transmission Rebuild Service Manual

[Sdean1982]

Thank you sir! I was looking for a manual like this.