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04 Sportsman 700 carb rear diff problem?

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Old May 24, 2020 | 10:30 AM
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Nomicron99's Avatar
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Range Rover
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From: North Idaho
Default 04 Sportsman 700 carb rear diff problem?

Hi.
So im pretty sure i need a new rear diff. Asked on another forum but no one seems to know!
Was given the 700 if i bought the one he was selling for 1K. 04 330 Magnum. The 330 runs and drives good with no problems as far as i can tell. Both needed new batteries and fresh gas. Last time licensed was 2008 so i assume last time used. He said they stopped using them when the 700 started making noise and did not want to make it worse.
The 700 however needed a new carb intake boot. Once it was running i took it for a short spin. Had a terrible grinding noise and moving really slow it had kind of a catch to it that you could feel for a split second like gears hitting and i could see the rear driveshaft jumping. Thought it was the transmission but i could not find anything wrong once removed and had a look inside.
Put transmission back and removed the rear diff although it also felt good turning it by hand. When i took the pinion out this is what a see. Comparing with a new pinion picture mine looks like its getting thin at the crown. Ring gear does look ok though.
Put some Prussian Blue on the gears and it sure looks like the teeth are contacting out at the very crown and might be starting to actually hit when under a load although no evidence of that.
Anyway before i buy a used diff im wonder if you think the pinion is indeed bad and if so can i just put a new pinion in it or not. If not ill buy a used diff.
Thanks for any help.


 
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