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09-07-2010, 08:56 AM
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Junior Member
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Member #7062
Join Date: Sep 2010
Location: Western New York
Posts: 5
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Left rear axle shaft removal.
Hello, all. I'm new here. This is the first time I've ever been really stumped regarding a repair to my machine.
I have a 2004 Sportman 400 4x4. The left rear axle shaft blew apart into pieces. All thats left is the "bell" portion of the axle where it goes into the transmission. I cannot figure out a way to remove it. Since the renmaining portion of the shaft is no longer attached, I can't give it a "sharp" pull to remove it from the tranny. Any suggestions? I have a brand new axle waiting to be installed and get me back on the trail. Any help would be greatly appreciated. Thanks all.
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09-07-2010, 05:44 PM
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Polaris ATV Junkie!
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Member #1958
Join Date: Nov 2009
Location: SE Kentucky
Posts: 781
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WOW!! You might try a slide hammer if you can get access to one or maybe weld a bar across the end and put both feet on the trans and pull like heck.
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09-07-2010, 06:15 PM
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Super Moderator
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Member #193
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 9,962
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Welcome to the board! 
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09-08-2010, 05:26 AM
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Junior Member
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Member #7062
Join Date: Sep 2010
Location: Western New York
Posts: 5
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Thanks.
I've been thinking that I may just drill a couple holes on each side of the cv "bell", put a bolt through and use a slide hammer or just hook up a chain a give it a tug. It's some pretty hard steel, I'm sure its time to go buy some drill bits.
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09-20-2010, 09:03 AM
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Junior Member
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Member #7420
Join Date: Sep 2010
Location: Cincinnati, OH
Posts: 7
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First off, this is my first post to this site at least.
Chazzo~ Take a straight pry bar and place it between the Cup and the diff, give it a tap with a heavy hammer. Turn the other axle a quarter turn and repeat. It might take a few minutes but the cup will pop right out. It is a good idea to soak it in Penetrating oil for a day before you proceed (if you sink the rear esp in mud/water a lot). I just did my right rear last week. Good luck and if you have any questions, let me know.
Digger
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09-20-2010, 10:36 AM
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Junior Member
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Member #7062
Join Date: Sep 2010
Location: Western New York
Posts: 5
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Digger, thanks for your reply. I did exactly as you stated, that was my first brainstorm. I let it soak and resoak for a couple days in PB Blaster. It just wouldn't move. What I finally ended up doing was, cutting 4 grooves in the cup with a cut off wheel and die grinder. I then welded a 4 claw puller to a slide hammer. After 3-4 pulls, it came right out.
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09-20-2010, 11:46 AM
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Junior Member
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Member #7420
Join Date: Sep 2010
Location: Cincinnati, OH
Posts: 7
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Hey that works too! Although I will say that the other way you can re use the cup. To install the new axle: hold it straight and tap it in with a rubber mallet. Easy!
Here is why I had to rebuild mine!
__________________
Digger
05 Sportsman 700
2" lift
Clutch kit
3 light mod
28" MudZillas
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09-21-2010, 08:20 AM
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Junior Member
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Member #7062
Join Date: Sep 2010
Location: Western New York
Posts: 5
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The cup wasn't worth reusing. I blew the axle apart, like nothing I've ever seen before. The new axle is in, and the machine is back on the trail.
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09-21-2010, 09:28 AM
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Junior Member
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Member #7420
Join Date: Sep 2010
Location: Cincinnati, OH
Posts: 7
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Chazzo~ Where did you get your axle? If you don't mind me asking, how much did you pay for it? Always looking for spare parts just in case. Are you running a lift or larger tires?
__________________
Digger
05 Sportsman 700
2" lift
Clutch kit
3 light mod
28" MudZillas
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09-21-2010, 10:42 AM
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Junior Member
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Member #7062
Join Date: Sep 2010
Location: Western New York
Posts: 5
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I got this axle from superatv.com, I paid $180 which included shipping for a brand new axle. It wasn't an OE axle($300 at the dealer), but it is definitely better quality. No, I do not have larger tires or a lift. I mostly use it for around the property for various jobs. Only occasionally do I hit the trails.
I've also purchased ATV axles at americancvstore.com, they were a little bit higher this time.
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