I have the low/reverse shift shaft seeping oil. Been doing it for a couple of seasons when I do the bush hogging. After that weekend work out it's not bad during the hunting season, Well now it is...lol

My question is can the seal (oring) be replaced with the transmission still in the 4wheeler? Part break downs shows snap ring,washer and oring. All the manuals seems to read that the case needs to be split and shaft removed. Hoping I'm just reading too much into it.

2001 sportsman 400 4x4

 

Shift shafts install from inside the case upwards. The o-ring is installed first then the washer and circlip as you've mentioned. Some how you'd have to hold the shaft after removing the circlip and washer and try to either pick the o-ring out or push it down to where you could install a new one in its place. That is if the shaft area allows enough room to do this.If not the case would have to be split. Plus if you're running too much AGL or different fluid or the transmission vent is partially blocked,this could be the cause? Oil seepage shouldn't be that much of a problem on the shafts leaking. At least on the ones I've worked on over the years even with ones that have had hard use with brush hogs,etc,BUT anythings possible.

 

Thank's for the advice. Never crossed my mind on the vent. I will check the level and the vent before I tear it up....lol Thanks again OPT your advice on the voltage regulator was dead on the money that you gave a couple of weeks ago.