Hey there guys,

I just recently found out about this forum. Been reading the posts about the CV boot replacement after I tore a boot riding around yesterday. So after gathering all the info I could from here I decided to tackle it on my onw. Everything went good until I had to remove the axle from the transmission. I pulled and pulled but it wouldn't budge. It ended up that I seperated the the upper (inner) CV joint and the axle is still in the gearcase. Now what? If you guys could lend some advice it would be much appreciated?

My quad is a 2004.5 Sportsman 600.

Thanks for the help,

Paul.

 

thats the first i have heard of that happening. you may have to put some penetrating oil like pb baster spray in where the shaft goes into the gear case as there is just a c lip in there holding it into place and when you get mud and grime built up it tends to rust and make it hard to come out. the proper way to get it out is to snap it as you try to pull it instead of a steady strain. soem times you need to use a pry bar as well behind it to help when your snapping it. becareful not to break the trans. case as its only alum. i guess if it were me i put push it back in a little and use 2 pry bars one on each side and try to snap it out. good luck.

 

i had a similar problem about a week ago... i looped some rope around the cv and applied tension then used pry bars to work it out of the tranny case, i always apply never seeze to the inside splines to prevent it from rusting up and becoming a real pain to remove... good luck

 

So you tied some rope around the upper cv joint and pulled while someone else pried it out against the transmission. I'll go home and try that tonight after work. I sprayed WD-40 where the shaft enters the tranny this morning before work so hopefully that helps as well. Thanks for the help guys.

I assume the upper CV joint can be re-assembled similar to lower one (seeing as how I pulled it apart). Does it contain that small circlip that the lower one does? Do you guys replace the circlip in the CV joint when you re-install the joints? I know I looked at the Polaris replacement CV boot kit but I can't remember if they included a new circlip.

I thought I saw a video link to Youtube on this forum that showed a guy taking off the factory CV boot clamps with a pair of pliers. Is that possible or was I dreaming...

Seeing as how a pulled the upper CV joint apart if I could remove the big side clamp on the upper CV joint I could take the axle off there and replace the lower boot (the one that originally ripped) and reinstall the upper joint and be done. Correct? Or am I going nuts...

 

if you take a look at my pics.(the camera icon under my icon on my ID) and go to picture no#12 you will see a pic. of what one looks like and the inside clip that holds it onto the spinned shaft. the boot clamps are what they call an ears style and requires a special pair of pliers to take off and put on. some of us have used a pair of needle nose pliers(i modified a pair)to fit the small ear part of the clamp to use instead of buying one. its very important to make sure you have got the clamp 100% on correctly and tight as if not the water will get in and ruin the cv joint. as far as a new C clip, unless you break it you wont need a new one.

 

Ok thanks for the help stendori. I'll see if I can get her fixed up tonight.

 

on my 00' i reused the clip. your best bet is to use prybars the first time. iv never yanked on the shaft to pull it out of the tranny. to remove the shaft iv put the shaft in a vice. used a needle nose pliers or 2 flat screw drivers and spreaded the clip. then pulled the cv joint off. just a thought "id replace both. save some time. i did one at a time before. but just a short time later the other tore on the same time. just a thought. dont have to.

good luck

 

Sometimes if Ya have enough room You can clamp a pair of vicegrips onto the axle then strike the vicegrips with a hammer to get them popped out.Might have to put a steady pull on it and then strike the vicegrips.

 

just becareful not to mark up the shaft where the boot sits on to hurt the seal.

 

Ya man stay away from that area.