a stuck slip yoke
 

ok guys i need help , im changing u joints on the front prop shaft and ive gotten it loose from the front diff but it will not slide off the output shaft of the tranny. Im sure this thing hasnt been greased in years so thats prolly why it stuck , i need some tips on how to free it up and get it off !!! any help is appreciated and thanks in advance !!!!! oh yea ita 2004.5 sportsman 700 efi

Best way without busting your knuckles with a punch and hammer is to use an air impact on the yoke body to drive it forward off the gear case shaft. Have the front yoke to the left of the front diff so it can clear it and should impact right off.

OK I finally got access to a air hammer , it moved forward about a half inch and now won't budge no more !!! Its right at the start of the splines and stops ! It will slide back pretty easy ! I made sure nothing was hitting from the rest of the shaft and stopping it ! This damn thing bout to get the best of me !!!¡

PB Blaster/Wd40 on the splines and heat the yoke with a torch. Impact it back and forth a little.May have to do this a couple times,but the yoke will pop off the shaft. IF the yoke splines are worn,may have jumped teeth on the shaft and will be harder to remove,but will come off. The shaft splines are way harder than the prop shaft yoke so it shouldn't be hurt. If the yoke splines are damaged,it'd be cheaper to replace the prop shaft as any assembly rather than trying to rebuild it.Hopefully it's just frozen from corrosion over the years.

Oh and on top of all that , i see water dripping out of the water pump weep hole ! Im assuming its the water pump seal thsts leaking on it ? Im sure ill be asking for advice on that too !

Yep,water pump seal leaking..Always seems like when you're fixing one thing you look around and find something else that needs repairing. Had to call a lot of people over the years on things like this to get approval to repair something else that wasn't on the original repair order.. :go crazy:

Ok so I tried heating it up and hammering it off and didn't work! What other options do I have ? I thought about getting a cutting torch and cutting the yoke down the middle , scared it may hurt the tranny output shaft tho ! Is there any other options ??

Man,I've never had one that I couldn't get off someway or another. Cutting torch may not be the best way if you damage the gear case shaft splines. Hard to get a cutting wheel in this area unless you are able to get to it from underneath,but more controllable as far as depth.You could possibly cut a V notch taking care not to hit the shaft splines and see if you could break a section of the yoke away. Then it should be easy to remove what's left.

Man that damn thing will slide right to where the splines about to start and jus stop ! It'll slide back and forth with no problem but jus wont go no further ! It's like there's something at the end of the yoke that's keeping it from sliding off the splines ! I'm gonna hafta have a new prop shaft for sure , this one is fubar ! I guess I'll try getting under it and hopefully the cutting wheel will be able to reach it !

Ok so I was thinking , jus how hot should I get it ? All I had was a lil hand help propane torch , it got hot but maybe it didn't get hot enough ?

Just heat that yoke up pretty hot with the propane torch and zap it again with the impact. Impact it at the front of the yoke not at the rear. Less chance of damage to the splines,plus the heavier duty the impact is,the easier it is too get the yoke off.Again if you have to tear up the yoke to get it off,just replace the whole prop shaft and be done with it.

Ok so I finally got it ! I ended up having remove rear driveshaft , unbolted the trans and cocked it over enough to stick out the yoke so I could get my grinder in there and cut out slots in the end of the yoke and it came off ! Now to reassemble everything while I wait on my driveshaft to come in !! Thanks OPT for you help !

Don't thank me,you're the one that did all the work to get that blame thing off! :D

Ok I got a question, after reinstalling the rear driveshaft and bolting up the reared and all the other stuff I had to do , I realize I didn't line up the holes on the yoke and output shaft for the dowel to go back in ! Is it necessary to have that pin in the yoke ???

Yes you need the roll pin!! The shaft can move backwards as you well know. If it ever moved back far enough to slide off the front diff,all hell can break loose. You could possibly be hurt or the shaft could even crack the engine case.. Just slide the shaft a little off the front diff,roll the atv back and forth to line up the holes,drive the yoke on the diff,insert the new spring pin using a dull bit and air impact. Always replace the roll pin. If you didn't order one,just get one at any hardware/auto store.

No it wasn't the front diff , it was the rear diff ! It's such a pain in the butt to unbolting the rear diff to slide it back , but I don't want wanna cause no more problems with it jus becuz I wanna be lazy!

Don't be lazy! :) even that short prop shaft needs the roll pin. PLUS on some 700s the roll pin actually would vibrate out and start to groove up the top of the transmission case,some even all the way through. Some people just replaced the roll pin with a hardened bolt and nut. Just a heads up on this one.http://www.trackshare.com/forum/showthread.php?t=15564