I own a 99 xplorer 400 4x4 (chain drive) and am in the process of replacing the rear disc, sproket and chain. After over an hour of prying, heating and spraying penetrating oil into that aluminum cover that "slides" over the axle nut, I finally was able to get that darn thing off. Then it took me 15 minutes of scraping and scrubbing to remove the gunk that was built up on the cover and axle.

I was going to change out the bearings, but am having problems loosening the axle nuts (found some advice on another thread). I have a couple of questions; 1) is there an easier way to remove those aluminum covers (I was going to remove the right side so if I need to get in there again, it wouldn't be such a pain, 2) is there anything I can apply to the axle (nut) before I slide the cover back on that would prevent these things from bonding to the axle?

Any tricks or tips would be greatly appreciated.

 

Try lots of heat first. I used a 3 foot pipe over a pipe wrench and it popped and cracked all the way off. It may be easier to cut the old nut off with an exhaust disc cutter then clean up the threads on the axle and replace the nuts. PITA either way you go but cutting is quicker. Dont cut too deep and damage the axle. Use lots of never-seize on assembly.

Steve