my stock 2001 foreman 450ES keeps popping the shafts out of the front differential. The first time, it took quite an effort to line it up and push it back into place. Now it seems almost effortless, I can pop the joint back ito place in about 30 seconds, just the proper allignment of the gears, a roll foward or back about 2 inches, and the push of the hand, it will slip back into the diff. The first time or two it was the right side front shaft, then every other time, maybe 3-4 times, has been the left side.

I'm not afraid to pull it all apart, i just don't really know what to look for. should i start by just pulling the diff out and apart looking for some sort of retainer clip? should i inspect the cv joints for play or wear first? I'm not so worried about pulling it all apart, it's knowing what to look for, and getting it back together that would be the problem.

I realized last night, when it happened twice in 10 minutes, that the differential must be dry of oil and probably leaking in dirt and water, so it must be fixed immediatly. I came back home, cleaned it thoroughly, so I could park it in the garage, and put the front end up on blocks, now what.....

 

update 1120 pm
I got the front left swing arms, shock, and shaft removed. I'm stuck on the right side. The shock and 2 swing arms are free, but the shaft wont give. I've got to get that shaft out before i can pull the differential.

any suggestions?

 

what a newb I am...... i found a great post from "honda mechanic" about 3 months ago. Full diagrams and explanations, thanks Dude!


I'm still stuck on getting the shaft loose on one side, whats the procedure to get that retaining ring out if it seems to be holding up well ?

 

You have to kind of push the shaft on , then give it a quick hard yank to remove it , sometimes we have to even use a prybar to hold tension to remove some that don't want to come apart.. They will come out if the retainer ring (snap ring) is bad , I would install a new retainer ring (snap ring) once you check the differential for dirt etc.

 

well i managed to get the diff out and onto the ground with the left axel still attached. I had to pull the steering linkage, front shaft, and get the thing turned around inside of the frame. With EXTREME wedging, prying, and hammering - the left axel still wont free up from the diff. So i just pulled the cover off the diff and drained the milky wet dirty gear oil into a pan. and what a freaking pain in the azz for a freaking $1 snap ring !!!!I still cant get to the other side of the main gear to get that second axel loose. Is is safe to assume that the snap ring on that side is doing it's job well enough to not worry with replacing? hahaha

What should i use to clean and flush the rest of that nasty soupy oil from the diff?
(one freind told me gasoline, another told me the expensive stuff from auto store)

and shouldn't the main gear come off even if the axel is stuck? i would like to tear down the whole diff to clean it, but hell i cant get the first part off either side.
or should i just flush it real well with a grease cleaner and slap the cover back into place?