If you take the diff out you can slpit the case to get better access to the broken shaft. You wont have to worry about not having enough room to get to the shaft. With all the time that you are wasteing to figure out what to do, you could have had the diff out, apart and put back together by now. Now you are going to waste more time to jimmy rig a way to get it out and thats not even 100% going to work. It will take about 1 hr to get the diff out. 5min to split the case and another 5 to pop the broken peice out. The whole job will take no more than 3-4 hrs. You are going on about 1 month to figure out the easiest way to get it out. Not so easy now is it? Do it the right way the first time. Its as simple as that.

 

AHMEN BROTHER!!!!!!!!!!!!!!!!!!

 

Heck, Twomanytoys could have walked down there, fixed it and walked back home a few times and probably still had time to get some rides in between times.

 

im trying to figure out how to fix it, and have been working at it, to no avail.
i dont understand how its getting out of control.
new axle aint a biggie, ive got one sitting right here.
im trying to find the best possible solution, and you seem not to care.
i ride my quad hard and have already broken and fixed many items.
if i need help, i know not to ask you.

 

I find it hard to believe that if you took out the opposite side axle you can't pound it out from the non broke axle side. You said it was lose in there. Take a brass punch and put it in the hole you made by taking out the other axle and hit it. It will come out. I talked to my buddy( is a Polaris mech.) and they do it often that way. Read it one more time, HIT IT!!!!

 

Sorry Bigdog, it don't work that way up front at least not on the front diffs with the central Hillard. I have my front axles out right now and there's no pass through, just solid steel.

TJ700 I feel your pain. I know your looking for a way to fix this at home without tearing your machine all apart. I know from experience that even with complete axles they are a bear to get out. So drilling seems out of the question since the axle spline is hardend. Maybe someone could TIG weld an eye bolt on the axle stub without cooking the diff seal, an experienced welder can tell you. Good luck, you'll get it.

 

ive been trying to get it out and taking the case apart isnt gonna make it any easier.
i dont understand your meanings.
the splined end the shaft slides into is SEALED on the other side, it will not pop out from the other side.
if fixing it by taking the case apart would have done it, i would have.

anywho. im on my own.
i wont bother to ask for help from you either.

 

02 sportsman 700 carbed.
sorry, cant access it with the other axle out.
tried it.
both sides are sealed.

 

Your right you cant pop it out from the opposite side because the output hub on both sides is solid in the middle. The axle slides into the output hubs. . If you split the case the case comes off seperate leaving the outer part of the hub shaft exposed. The entire guts come apart from the case so you can access the broken half. I know this for a fact. I have a case and can give you digital pictures that show you can access the broken shaft if you split the cases.

 

I think there are three different front diffs out there. Im not sure ,but have you went to the Polaris web site and on the parts list looked at a exploded view of your diff. It may help, just a suggestion.