Ok, heres my situation

I havent ridden the scram in at least 8 or 9 months...

missed out on a great winter,
but anyway

Last summer, I was riding a few miles from my house, with
my buddy on his 89 warrior.

We were in a field, and I was driving along, and my Rear sprocket hub
snapped at all 3 bolt holes, and sent the chain right up bunched around the
trans case.

So, first I thought I just needed a new hub, and I thought that was
going to be easy.

So I bought a used hub off a 97, and had my friend acid dip and sand blast it, looks brand new now.

Went to do the install, pulled the wheels, the wheel hubs, and
got to those DAMNED axel nuts.

Well, a Bottle of propane later, and I got it red enough to slowly remove, and than
the 2nd nut, was just as tough... Took 30 mins to an hour of
brutal work to remove it, torching and turning with a big ***
1 3/4. So FINALLY, them off, and try to remove the hub, that should, theoretically
slide out. So its not budging, things get desparate, we try heating it up a bit,
but our torch isnt good enough to get this thing red hot.

By now, im positive all my seals and o rings are melted

Still cant budge this thing, let it sit, come back to it later,
soak it multiple times in liquid wrench , still no luck.

So , we go ahead and pull the axel, and throw the whole
thing in a big Vice I have,

Try prying, and hammering, and putting metal bars to it, to hit it off..
2 people at a time, both sides for even pressure...
All that happens is chunks of the carrier fall right off, to revel the bearing underneath... So thats a bust..

At this point i dont give a *****, I even cut thru one side with a dremel, the WHOLE
Hub, and split the last tiny bit with a punch, so now this thing is split on one side.. it stillllllll will not budge........ !!!!!!!!!!!!!!!


So, Since i need it, i order another housing complete with all the crap inside, but the bearings are shot ( i have new bearings and seals waiting tho)

The new one gets here today, its dirty as can be, and in digging the dirt off, i find
a small chunk of broken aluminum (or whatever it is) on the outside, doesnlt look
like a critical spot,and Im sure I can still use it, or weld the little chunk back on.

Anyway, i have a new chain and sprocket set comming also..


I realized i only bought the outer bearings and seals, and that theres
a spacer bearing, and a tube bearing in side there..
I can give the whole thing, with the new bearings and seals, to my
friend at a machine shop,

Is the Clip ring re usable?

Any advice?

Can i slap the housing togather, and
put the axle thru later?

Im probably going to have to melt the old hub off,

Basically Everything besides the axel its self, the clip, the sleeve, and the spacer
is going to be new back there...

New hub, new chain and sprocket, new bearings, seals,

Any advice for putting this back togather?
If I need to take it apart again later, i dont want this much
pain to go thru... Im polishing my whole zxel up and cleaning the splines..
the threads on the axel for the nuts are really fine..
can i go over them with a spinning wire brush?

 

??

 

assemble everything with antiseize,its a bottle of silver grease,autoparts store,it will come apart again when you want........

 

front sprocket needs to be changed,
How do I remove this?


From the breakout I see a bolt, and a retaining clip..

how does it come off?

 

retaining clip,done.

 

I dont' know a whole lot about tearing the axle down, but I weld for a living, and do know a good bit about that. If the chunck that broke off is aluminum, I wouldn't weld it if it is part of something that will be under a lot of stress. Welding aluminum weakens it.

 

FINALLY
Shes almost ready to go back togather,
I just have to get the Small Sprocket and the bunched up chain out,
and reassemble the axle.
I was at a machine shop last night sandblasting, ultrasonic cleaning
, and buffing things, The carrier looks great now, as do my wheel hubs,
Polished the sleeve bearing up, it was dirty with rust, now its shiny
as can be, Cut the old hub off, got the new bearings in

Ok, i dont want to sound dumb, but how do I get that retaining ring off?
Snap ring pliers?

 

yeah,or two little screw drivers....