I have found a crack in my golf cart differential!

I’ve just discovered a nasty crack in my golf cart’s differential, and it’s leaking oil like crazy. It’s messing up my cart’s performance big time. Has anyone dealt with something like this? I’m desperate for some advice on how to fix it.


Ran into a similar nightmare last season. I ended up welding the crack, but it wasn’t a walk in the park. Have you thought about welding it yourself or finding a replacement part? It might be your best bet.

Solutions that Worked for Users

SolutionUsers Who Found SuccessApprox. Cost (USD)Approx. Time Needed (Minutes)
Welding the Crack350-10060-120
Replacement of Differential/Part2100-300120-240
Heating Case Before Welding150-15090-180


  • Golf cart leaking oil from the differential area.
  • Visible crack in the differential casing.
  • Performance issues with the golf cart.

Possible Causes

  • Stress from improper installation or overtightening of components.
  • Wear and tear over time leading to cracks in the differential casing.

Solutions that Worked

  1. Welding the Crack
    • What I Did: Welded the crack in the differential casing.
    • Outcome: The leak stopped, and the differential’s integrity was restored.
    • Personal Experience: I had to clean the differential thoroughly and drill a hole at the end of the crack before welding. It was a delicate process.
    • Estimated Cost: $50-100
    • Time Needed: 60-120 minutes
    • Steps:
      1. Remove and disassemble the differential: Ensure you have a clean, flat workspace. Take photos as you disassemble for reference during reassembly.
      2. Clean the area around the crack thoroughly: Use a degreaser and a wire brush to remove any dirt, oil, or debris.
      3. Drill a small hole at each end of the crack: This prevents the crack from spreading further during the welding process.
      4. Weld the crack carefully: Use a MIG or TIG welder for better control and precision. If you’re not experienced with welding, consider getting professional help.
      5. Allow the welded area to cool down slowly: Avoid quenching as it can cause the metal to warp or crack again.
      6. Reassemble and reinstall the differential: Refer to the photos taken earlier to ensure everything goes back correctly.
    • Expert Tip: Preheat the area around the crack with a propane torch before welding. This helps in achieving a stronger and more durable weld.
  2. Replacement of Differential/Part
    • What I Did: Sourced and replaced the damaged differential or part.
    • Outcome: The golf cart was restored to full functionality.
    • Personal Experience: Finding the right part took some time, but it was worth it for a long-term fix.
    • Estimated Cost: $100-300
    • Time Needed: 120-240 minutes
    • Steps:
      1. Identify the exact model and year of your golf cart: Check the manual or identification plate on the cart for this information.
      2. Search for a replacement differential or part: Look for parts online, in golf cart forums, or through local dealers. Ensure the part is compatible with your model.
      3. Remove the damaged differential: Use the proper tools and take note of how everything is connected.
      4. Install the new differential or part: Follow the manufacturer’s guidelines for installation.
      5. Test the golf cart for any leaks or performance issues: Make sure there are no unusual noises and that the cart runs smoothly.
    • Expert Tip: Apply a new gasket or gasket maker when installing the new differential to prevent future leaks.
  3. Heating Case Before Welding
    • What I Did: Heated the entire differential case in an oven before welding.
    • Outcome: Successful welding without warping or additional stress.
    • Personal Experience: The preheating process was crucial for a successful weld.
    • Estimated Cost: $50-150
    • Time Needed: 90-180 minutes
    • Steps:
      1. Remove the differential case: Ensure all oil and other fluids are drained.
      2. Preheat an oven to 350°F: This temperature is typically sufficient for even heating.
      3. Place the differential case in the oven: Ensure it’s placed on a heat-resistant surface.
      4. Weld the crack while the case is still warm: This helps in reducing thermal stress on the metal.
      5. Allow the case to cool down evenly and slowly: Do not rush this process as it can affect the integrity of the weld.
    • Expert Tip: Check the differential case for any other potential weak spots or cracks before and after the heating process. Address them as needed to prevent future issues.

Golf Cart Models Where This Worked

  • 1994 Club Car Carryall II
  • Yamaha G16

Safety info

  • Regular Inspection: Regularly inspect your golf cart’s differential for any signs of wear or damage. Early detection can prevent more serious issues.
  • Use the Right Tools: Always use the right tools for disassembly and reassembly. This ensures a proper fit and avoids additional damage.
  • Seek Professional Advice: If you’re unsure about any step of the process, don’t hesitate to seek advice from a professional mechanic.

Extra tips

  • Alternative Solutions: In some cases, using an epoxy designed for metal can be a temporary fix for small cracks. However, this is not a long-term solution.
  • Preventative Measures: After repairing or replacing the differential, consider using a protective cover or skid plate to prevent future damage, especially if you frequently drive in rough terrain.


Ernie loves documenting interesting facts about golf.

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