Removing rear axle

[jonslink]

Hey, I'm sure this has come up several times. I was trying to take out my rear axle and it disconnected right at the rear differtial, it's where the small shaft goes into the big cylinder..(sorry not a mechanic) anyways now I'm stuck with getting the short fat cylinder out.... Any help would be great....also how hard is it to replace the seals where these axles go into the rear differtial? Thanks
This is 2002 sportsman 700 twin. Manufactured 03/02

[focushunter]

Should be able to pop it rigjt out. Stick a pry bar in it just make ur not to use your diff to pry on.

[jonslink]

Originally Posted by focushunter

Should be able to pop it rigjt out. Stick a pry bar in it just make ur not to use your diff to pry on.

Ok thanks I soaked it in PB blaster last night, I'm gonna try taking a pry bar to it this evening.

[POLARIS13]

i had to change the seals in my 09 800 EFI and you have to take both axles out, and disconnect the rear diff....there are alot of bolts, so remember where you got them out of, because some bolts go all the way through and some just screw in the diff to hold it there. but thats just for mine, not sure on yours. and as the axles go, just stick a bar in between like FOCUSHUNTER said...but its alright if you pry on the case...wont hurt it at all....it is aluminum so it will scratch with your bar, but nothing to worry about.

Once you get everything off, the case can be taken out. Remember to disconnect the vent tube. after that, take off the 8 or so bolts holding it together. get it open and the big disc gear will come out. Take a socket or section of tube that is the right size and pound out the old seals....putting the new ones in is a little tricky! After you have it all done, i would suggest putting a silicon gasket maker in the place where the two halfs come together. Any questions, just ask. I have had my rear diff out 3 times to figure out what a noise was, and once to change the seals!

[jonslink]

Originally Posted by POLARIS13

i had to change the seals in my 09 800 EFI and you have to take both axles out, and disconnect the rear diff....there are alot of bolts, so remember where you got them out of, because some bolts go all the way through and some just screw in the diff to hold it there. but thats just for mine, not sure on yours. and as the axles go, just stick a bar in between like FOCUSHUNTER said...but its alright if you pry on the case...wont hurt it at all....it is aluminum so it will scratch with your bar, but nothing to worry about.

Once you get everything off, the case can be taken out. Remember to disconnect the vent tube. after that, take off the 8 or so bolts holding it together. get it open and the big disc gear will come out. Take a socket or section of tube that is the right size and pound out the old seals....putting the new ones in is a little tricky! After you have it all done, i would suggest putting a silicon gasket maker in the place where the two halfs come together. Any questions, just ask. I have had my rear diff out 3 times to figure out what a noise was, and once to change the seals!

Ok thanks, I'm still having a hell of a time getting the rear axle out.i ordered a cv puller that should be here in a day or 2( got speedy shipping I'm so frusturated with it) I know the axles haven't been pulled since they were put in so I imagine there rusted pretty good. I'll keep you posted how it goes when the puller gets in.

[POLARIS13]

Originally Posted by jonslink

Ok thanks, I'm still having a hell of a time getting the rear axle out.i ordered a cv puller that should be here in a day or 2( got speedy shipping I'm so frusturated with it) I know the axles haven't been pulled since they were put in so I imagine there rusted pretty good. I'll keep you posted how it goes when the puller gets in.

I personally think they are a waste of my money....just cause there is always something in the shop that can be fabbed up to make things work. but keep pounding on the shaft....it will break freee...if you have a buddy or somebody else that could do it from equal sides, that helps tremendously! otherwise, keep me informed on how the puller works..i might get an idea from it! haha

[focushunter]

Get someone to jerk on it while you pull. And make sure when putting the new one in put a little grease on it.

[jonslink]

Well the cv puller is worth the money! 3 pulls and it was out..now onto the seals my parts guy said these were serviceable from the outside of the diff, once I got the old one out I saw a set of bearings...did I screw up or is this normal?

[POLARIS13]

Okay...but no, that is normal....inside the rear diff is a gear on the shaft where the rear axle goes into. there is a bearing on each side of that gear. You are fine! is the diff still in the wheeler!? or did you take it out!?

[jonslink]

I kept the diff in the four wheeler..the parts man said i should be able to find a seal at local car parts place..do I just pop the new seal in and good to go??