I have one at a shop where the rear axle is extremely stuck and we are looking for ideas on getting this thing out without breaking the diff case.
They have tried 8 lb. slide hammer, prybars with equal pressure with air chisel for vibration, lots of PB blaster, some heat, etc.

They are about out of options on how to get this thing out. They are experienced with ATV's , so they are competent.

Any suggestions would be appreciated.

 

Sounds like everything and more that I have seen anyone do. I know for me it was one of things I kept tryimg everyday for about a week and kept adding Wd-40 or PB Blaster for days and days and eventually one day when I was pulling on it, it just popped out. I would keep soaking it and trying to manipulate each day. It may take awhile for the corrosion to loosen up to get the axle out. Maybe OPT(our expert on this site) will have some better solution for you. Welcome to the forum!!

 

I just went though this a month or so ago . I ended up using cutting torches and blowing holes in the steel cv axle cup's both sides ( axles pulled out of cv cup ) I then dropped a bolt though the holes with a chain attached in the middle and attached the chain to a slide hammer . After maybe 1/2 hour I got it out . One side no way was it coming out so after I got the other side out I drove the really stuck axle out from the other side . If your only trying to do one side and it won't come you might want to try the other side , get it out then drive the other side out . It's a pain but it will come , use anti seize on the spines on re- assembly

 

I have on a couple machines rather than do any damage as you mentioned after even using slide hammers, air chisels,heat,etc and letting sit overnight drenched in Pb blaster, have been able to remove the other drive shaft and have driven the frozen one out from the other side. Not a pleasant job anyway you look at it! OPT

 

Thanks, all. Does the 2005 Sportsman 700 EFI differential allow you to punch the axle out from the other side once you have the other axle out, or do you have to remove gears and stuff to do so?

 

Each front drive shaft goes in to a separate hub race that goes on either side of the front drive gear and just pull out,in other words no,you have to pull em both out not drive the other out as you can do in the rear. OPT

 

Hi Polaris tech. It is the rear axle that we can't get out. Can we punch one out from the other side in the rear diff?
Thanks

 

Just pulled my rear axles out last weekend to replace the seals that were leaking. I have a 2006 sportsman 800 and once i got one side out i was able to punch the other side out with a hammer.

 

SORRY! I shouldn't be answering questions at 3:30 in the morning!! YES as commented above on the REAR differential you can do this,NOT on the front! OPT