Well, during the last two weeks, I have completely torn down the EV to the frame. Sent the charger off and still waiting for it to come back. Replaced the DC/DC converter. Had the motor rebuilt. By this point, I just went ahead and took out the Sevcon controller, contactor, and the throttle sensor as that was all the electronics left from the firewall back. Bagged all the connectors and gave it a good power wash from the firewall back. Must of been a 100 pounds of mud up under the floor board! Cleaned the battery cables with baking soda and brushed them down with a wire wheel. I did stop short of repainting the frame and battery trays. The trays are in moderately bad shape and probably should be replaced. Frame is rusty but still seems very solid. But that is a project for the future, maybe once this thing proves that it will work and be useful for me::|. And I removed all of the wiring modifications for the replacement headlights, so I believe all the wiring is back to original - minus headlights. I will deal with that later.
Got all of the pieces put back together today, minus the charger. Not too happy with the results. I haven't got all of the details figured out, but it seems that it only wants to crawl in Low, move only slightly better in Max, and runs OK in High unless I try to start up a (gentle) slope from a dead stop. Then I have to back down and get a running start. I had AWD/Turf mode switch out as I am trying to fix the lights in it. So I put it back in, but ran out of time to determine if it really affected the behavior. Hopefully, I can spend some time on it tomorrow. I want to make sure I didn't leave anything unplugged, but I don't think I did. I checked each battery before putting them back in and they ranged from 12.3 to 12.4. I also plugged the meter in to the 48V plug that goes into the charger and had 49V. When I ran the EV, the voltage never dropped below 48V, even when the EV was in crawl mode. So I don't think the batteries are an issue. Checked the controller's green light while it was parked and the key on and it was on solid. Did not think to look at it while driving.
At this point, I don't even know where to begin. I guess it is possible that the motor isn't right, but not sure how to check it. Well, maybe after a good night's sleep, the brain will work better tomorrow. Of course, any suggestions will be greatly appreciated.