Hey Guys,
I'm a newbie here and was looking for a little help.

I have a 04 Magnum 330 4x4. Last week I ripped the wire that goes into the front diff that engages it. It actually broke off inside, so I have to take the front diff off and dissasemble it to get at it. Its ready to come out, however I can't figure out how to disconnect the front drive shaft. I used a punch to remove the pin, but It still won't slide off the splines. Any thoughts? Is it pressed on? Would it be easier to disconnect at the transfer case. Any help would be greatly appreciated.

Thanks guys!
Steve

PS great looking site, glad I found it.

 

It should slide off with a little force. You may need to pry it off or give it a few taps with a variable angle swing press [img]i/expressions/face-icon-small-smile.gif[/img]

 

Thanks for the reply Todd, you were right, it slide off with a little persuasion. Actually evenly applying the pressure really did the trick.

So anyways, thanks again dude!

You have a really sweet ATV todd. I can't wait to get tires for mine. Hopefully will be snorkeling out the bike this week end if all goes well

Also I thought the axles would just slide right out of the diff like a truck, but its like they are held in by a c-clip or something. Is there a way to pull the axles without getting into the diff?

I could not even imagine how much the dealer would have charged me for this fix!
Glad I can figure out/work on stuff myself. I'm still new to the ATV world but I'm learning.

 

I think the front axles should pull out. Put a prybar on one side and hold some pressure, and then tap the other side with your swing press and it should pop out. There is a circlip that holds the axle in the diff and probably some rust too.

As far as snorkeling, make sure if you do a few things, do them all. There is no point in doing your air intake and clutch without doing all the vent lines for the diff and trans and don't forget the overflow for the coolant!!

And welcome to the forums

 

Well I have My front diff all apart and it seems pretty basic, except for the fact that I can't get access to where the electric motor is that locks & unlocks the differential. The motor almost seems like it is built into the side of the casing. I guess worse case if I can't get into where the motor is, maybe I can order just the side of the differential that has the motor in it. When your standing in front of the bike facing it, its the whole left case of the differtial. Can I order just that side?
Or is there a special tool that pops the motor housing out of the case?
Thanks very much for any help or advice you guys may have with this.