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Old 01-25-2010, 02:58 PM
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Unhappy 2002 Sportsman 700 rear drive shaft removal

Trying to remove the left rear drive shaft assy on my 2002 Sportsman 700. I have the left rear hub assy off and the book says "pull outward sharply to remove from transmission". I have tryed this but nothing is moving. I know there is a ring that snaps into place during install but how much force is needed to get this thing to pop out? I have even taken the top cv joint out of the hub (the boot was split) and rigged a 3 jaw knocker puller (clamping the jaws against the remaining boot and band) with no luck. After this I rigged a regular 3 jaw clamping style puller, wedged a bar under the jacking threads to push against an outside reference. I have put enough force on this to start bending the bar. Have I missed something in the dissassembly? The example in the book (polaris service manual) is for the right side. Do you have to take that side off first, inorder to access a snap ring or something?

If anyone has done this before please reply

Thanks
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Old 01-25-2010, 03:46 PM
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Red face

I'm kinda in the same boat as you. I'm trying to remove the transmission and to so you have to remove both drive shafts, however niether one of them will pop out. I have tried "pulling sharply" on both drive shafts. I have also tried rigging something to the shaft ang jacking against frame. Nothing seems to be working.I dont want to damage the cv joints or the tranny case. I'm not sure what to do. I searched this forum and didn't come up with any answers. I guess my next option is a trip to my local polaris dealer, the mechanics there are always helpful, so stay posted i'll let you know if I find something out.
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Old 01-25-2010, 05:17 PM
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Old 01-29-2010, 08:51 AM
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I talked with my Polaris dealer and they said that the shafts should just pop out. Be sure you're pulling straight out on them and keep pulling. They said it may take alot of force and that you really cant hurt the cv joint. They suggested putting a chain around the shaft and pulling on it.So just keep yanking, good luck.
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Old 07-16-2010, 06:01 PM
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Quote:
Originally Posted by Biggs View Post
I'm kinda in the same boat as you. I'm trying to remove the transmission and to so you have to remove both drive shafts, however niether one of them will pop out. I have tried "pulling sharply" on both drive shafts. I have also tried rigging something to the shaft ang jacking against frame. Nothing seems to be working.I dont want to damage the cv joints or the tranny case. I'm not sure what to do. I searched this forum and didn't come up with any answers. I guess my next option is a trip to my local polaris dealer, the mechanics there are always helpful, so stay posted i'll let you know if I find something out.
Did you figure out how to get your half shafts out?
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Old 01-20-2011, 08:49 AM
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By now you've probably got it apart and fix! I had to use a couple of big screw drivers and carefully pry it from the gearcase. I place the screwdrivers close to the edge of the plunge joint casing. I ended up disconnecting the wheel end of the upper a-arm to get a straight shot to the gearcase.
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