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99 Xplorer 400 Rear Axle

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  #1  
Old 03-05-2009 | 01:06 PM
1greenhornet's Avatar
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From: Sheboygan
Default 99 Xplorer 400 Rear Axle

I recently decided to change out the worn seals on my rear carrier. After a couple hours of work I had removed the axle and carrier (those nuts are a you know what to get off). Anyway, after cleaning and wire brushing to get the axle and parts looking good, I put everything back together and finally filled the carrier with grease. After a while, the grease started coming back out of the zerk fitting (that should have been a sign), once it stopped overflowing, I put a couple more pumps in expecting to see a bit of grease coming out at the axle but instead I noticed the right seal was not flush in the carrier, then I heard a pop and noticed the left seal was about an inch out of the carrier and the bearing was out of the carrier.

Pulled it apart (comes apart much easier now) and pulled the axle part way out so I could re-install the seals. Put it back together, greased it up (I pumped maybe 10 times). I was afraid to put too much in again.

I would like to know the best way get the right amount of grease in the carrier. Should I wait until it warms up a bit to add the grease, stop when it comes out the zerk?

I do not want to go through the hassle of removing the axle and other parts required to get those seals in again.

Any help would be greatly appreciated.

GH
 
  #2  
Old 03-05-2009 | 09:35 PM
old polaris tech's Avatar
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From: North Texas
Default 99 Xplorer 400 Rear Axle

When seals and bearings replaced,8-10 pumps sufficient,THEN every 25 hrs or so give it a couple pumps. Seals wont pop out so easy if you use red loctite around seal when installing and let sit overnight before you add grease.
 
  #3  
Old 03-05-2009 | 10:38 PM
eggenz7's Avatar
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From: Troup, Tx
Default 99 Xplorer 400 Rear Axle

also the air thats already in the carrier has to compress to allow the grease in. something has to give some time.
 
  #4  
Old 03-24-2009 | 03:17 PM
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Default 99 Xplorer 400 Rear Axle

1greenhornet ..



I am trying to do the exact same thing as you, but unfortunatly i can't seem to remove the nut that holds the axle on. I've tried heating it up, alot of wd-40.. exct... nothing seems to break it loose. It's not reverse threads is it? What's the trick to removing that nut so i can replace the seals? Thanks for any help in advance.
 
  #5  
Old 03-24-2009 | 04:50 PM
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From: Montrose, MN
Default 99 Xplorer 400 Rear Axle

Cut the nut off. Make a couple relief cuts, chisel it off. Just be careful not to cut into the threads. Buy a new nut. I've taken them off with a pipe wrench/heat/BFH..what a crappy job that can be!! Cutting them off is much faster and the nuts aren't expensive.
 
  #6  
Old 03-24-2009 | 06:32 PM
eggenz7's Avatar
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From: Troup, Tx
Default 99 Xplorer 400 Rear Axle

<div class="FTQUOTE"><begin quote>Originally posted by: Wenty

Cut the nut off. Make a couple relief cuts, chisel it off. Just be careful not to cut into the threads. Buy a new nut. I've taken them off with a pipe wrench/heat/BFH..what a crappy job that can be!! Cutting them off is much faster and the nuts aren't expensive.</end quote></div>

agreed. those thread are so fine and shallow that you cant work any fluid inbtween there. just cut it off and buy a new one.
 
  #7  
Old 03-25-2009 | 08:51 AM
Slumdogg's Avatar
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Default 99 Xplorer 400 Rear Axle

Thanks Wenty and eggenz7. I actually thought of doing that but wasn't sure if i should or not. Guess i will. It's better than messing with that nut for several days and getting aggrevated. Thanks for the help.
 
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