Repair of EV splined motor coupling

[Erie Fred]

There is normally some form of shock damping built into most drive trains, if there isnt a sprung hub in the clutch or flywheel there will be rubber dougnuts in the driveline.Designers of these leccy jobs seem to have missed a trick, I would have thought its getting equally hammered in both acceleration and in power recovery deaccelerating.

Bob

You can fix it in the software.

 

[Pete.]

Stripped gearbox input splines is a bit of a problem on certain models of BMW bike. Everybody reckoned it’s because the bike isn’t stripped in half and the splines greased every couple of years.

But, research was done and apparently a certain quantity of gearboxes were manufactured incorrectly with the locating dowels offset by 0.5mm or so, which means the spline is continually being loaded eccentrically.

Maybe someone could look into this particular EV gearbox for some similar mass production cock up?

I don't agree with that theory I've had four of those model of bikes from 2002 to 2005 (the last year). The only one which has any sort of spline wear is the 2005 one.

 

[mcostello]

Maybe against all odds, You got a good one. Works for cars also.

 

[eddie49]

The EV forum member in Portugal has sent me the photos of the coupling after it was welded onto the worn transmission input shaft:

Looks like they drilled 4 holes in the splined sleeve and then TIG welded it?
The initial estimate for the job was 2,500 Euros.
I recommended lubricating the electric motor end of the coupling with molybdenum disulphide grease, but that looks like normal lithium grease. The oil seal does not look damaged. I have suggested that he tops up the gearbox oil ( 75W manual gear oil ) and keeps a careful eye on the level.

 

[Morrisman]

As well as fixing it solid, the welding may have caused the connector to pull off sideways, slight angle, due to the slack, which means it won’t align accurately with the motor spline.
I wonder how they stopped the oil seal melting.

 

[Blobber]

Well that wont be coming apart again (shakes head emoji)

 

[Bornfree]

Well if the shaft and coupling are both knackered it's worth a try, nothing to lose.

 

[Seadog]

Well if the shaft and coupling are both knackered it's worth a try, nothing to lose.

Except needing a new casting if they are.

 

[Bornfree]

Except needing a new casting if they are.

Why ?

 

[Seadog]

Assumption on my part about how the bearing is fitted.

 

[500e]

Looks like the whole mess will go back through the casing, another poor design and no recompense for the customer

 

[ranchero]

Except needing a new casting if they are.

and whatever that spline is attached to

 

[OJCar]

@eddie49

On e-bay

Peugeot Bipper Electric by Allied spares or repair​

£1,200.00

"September 2012 Peugeot Bipper which has a full electric conversion by Allied Vehicles of Glasgow.
Covered 15200 miles. Clean van which is complete and was working.
12 months mot, fault is vehicle will not ‘wake’ up upon completion of charge.
Maybe of use to somebody with same vehicle or repair?
Cash on collection "

Any use?

 

[eddie49]

The Allied Electric EV conversions were built for Glasgow City Council. They were a complete nightmare: badly designed, poorly constructed, never worked properly, unsupported, undocumented. It takes a lot to discourage me from taking on a hopeless project, but i would draw the line at an Allied EV!

 

[OJCar]

The Allied Electric EV conversions were built for Glasgow City Council. They were a complete nightmare: badly designed, poorly constructed, never worked properly, unsupported, undocumented. It takes a lot to discourage me from taking on a hopeless project, but i would draw the line at an Allied EV!

Sounds like GCC at their best !

Thanks.