The new and improved controller arrived. Peter found nothing obviously wrong, but added some small improvements. However, the horrible sound, smell and shudder persisted.
I know of no mechanic around here who works on electric conversion vehicles. All the repair books begin with something like, “remove the battery cable.” Well, I have 19 of them. The old-school methods will not work. But, I still thought that maybe someone might recognize the sound. The problem could be the transmission, differential unit or even the brakes?
Clyde, a friend well versed in auto mechanics, came by to see what he could find. He wasn’t sure what was wrong until he saw the smoke and fire shooting out of the side of the motor. I put the truck in neutral and spun the motor to about 3500 RPMs and replicated the problem.
This weekend, I removed most of the components under the hood. This evening, amid the heat and humidity, I extracted the motor, removed the clutch, flywheel, hub and mounting bracket. It took many days to assemble and install those but only 4 hours to remove them. Later this week, I will ship the motor off to be repaired.
I don’t know if my tenacity is a blessing or a curse.