Welcome to the board!:cowboy:

 

you will need to open the split the housing in half also,the main axle and gear are splined.On a 2000 there is a circle clip way down in side thats a bear to remove.On a 2002 it was redesigned and is not there.Ihavent rebuilt an 01 but have done a 2000,and 2002.Do yourself a favor and change that one outer bearing,they get crap in them.Also renew the slip spline on the driveshaft while its out,and be sure to check them ujoints
ALAN

 

Almost there!

Thanks Alan

Yes of course it would be on a spline , made sense after you posted.
So I pulled it all apart have seperated gearbox, axle and outer axle housing. Want to change all my seals. I want to clean and check gearbox while I am here.I have got the gearbox shells seperated by about 10mm and won't go no further, I am sure it must just be the 2 axle seals holding it together but don't want to force it too much. Is there anything I am missing?

Thanks for all input

 

Thanks Alan

Yes of course it would be on a spline , made sense after you posted.
So I pulled it all apart have seperated gearbox, axle and outer axle housing. Want to change all my seals. I want to clean and check gearbox while I am here.I have got the gearbox shells seperated by about 10mm and won't go no further, I am sure it must just be the 2 axle seals holding it together but don't want to force it too much. Is there anything I am missing?

Thanks for all input

You took the 4 bolts out of the front and removed the small gear right?I beleve at this point if you have some seperation its just a matter of you getting it "off the bearing" .There is a large o ring between the halfs too.Im a day late in checking this post ,i bet you got it already.
Just a side note the one thing that always wore and had to be replaced on my magnums was the aluminum hubs the wheels hook too.Make sure they aint sloppy ,and like i said while you got it apart replace that slip spline coupler on the drive line.
ALAN

 

All in bits

Hi Allan

thanks

Got it apart, yes it was just the bearings holding it in.Its like trying to open a real tough oyster, and stripped it down completely.
The bearing holding the small pinion shaft had shattered 2 balls and flogged the seal out. The axle seals were leaking as well, cleaned out all the crap that had got inside (heaps) and had a good look at it. There must have been a little cup bearing that sat in a hole to take the end of the pinion shaft into the gear box, this had worn right out and the end of the shaft has started to ovalise the housing. I will need to take it to an engineer friend to see what he thinks, I am wondering if I can machine this out larger and place a larger cup to take the end of pinion shaft.
Removed the seal and 2 bearings from outer axle as that was all fill of crap as this seal must have failed as well. The bearing on the inside was hard to remove and probably should have just left it in there in hindsight.
It gets better!
Cleaned the axle down and found a crack right around the surface where the bearing on the outer axle loads on to the axle next to the gearbox.
I cant understand how you can have a continuous fine crack right around the surface but still be in one piece. Maybe it is just on axle surface?
I will show to an engineer.
so now will price up all bearings etc and look at what the best approach is I am really annoyed I found the crack in the axle, I wonder if I had never seen it put it back together whether it would of never failed again. I don,t ride ATVS hard or fast, just use it to access the beach I live at to go swimming and surfing.

thanks for your input

Phil

 

Hi Allan

The axle seals were leaking as well, cleaned out all the crap that had got inside (heaps) and had a good look at it.
Removed the seal and 2 bearings from outer axle as that was all fill of crap as this seal must have failed as well.

Phil

PHIL,as you can see,crap will get by the seals,even if you dont try to drown it
This is why i try to avoid water if i can .In my experience any seal will leak if its submerged long enough,ive had many failures because of it.On a bearing i would rather see a grease fitting to force the water out.No such thing as a sealed bearing in my book.It tickles me to see these guys put snorkles on their bikes,and use them like they were boats,for crying out loud.Then you see them post how their POLARIS is a peice of crap,because something aint working right.Or you see them posting videos of them beating the piss out of their machine and doing the same .Yes they are allterrain vehicles ,but that doesnt mean they are boats ,or built like army tanks:tongue2:iPOST THIS AND MY AVATAR SHOWS ME DRIVING THROUGH A WATER HOLE
ALAN

 

I stripped put the splines where the big gear goes on the axle,on my 02 this summer .It looked as though it rusted a bit and that started it.Most would probably bought a new shaft and new gear,at around 1500 bucks.Not me i welded it to the shaft.The funny part is the drive line is quieter than ever,and not a bit of vibration at high speeds.So it cost me a little bit of gas and mig wire for my welder and im good to go.
ALAN

 

End of pinion shaft bearing

Hi Allan

Can you remember the shape of the small bearing/housing that holds the end of the pinion shaft in the gearbox housing. There is almost nothing left of this one I was originally thinking it must be cupped shape but now am realising it would probably just be a ring shape? I have checked the drawing but the detail is so small cant see.
Have you replaced or remember this item when working on yours.

Once again thanks for all your help

Phil

 

Hi Allan

Can you remember the shape of the small bearing/housing that holds the end of the pinion shaft in the gearbox housing. There is almost nothing left of this one I was originally thinking it must be cupped shape but now am realising it would probably just be a ring shape? I have checked the drawing but the detail is so small cant see.
Have you replaced or remember this item when working on yours.

Once again thanks for all your help

Phil

sorry its not ringing any bells

 

Sorry to resurrect an old thread,but I'm fixing to tear into my gearbox also. I have a sercive manual, but it does not cover going into the gearbox. It's a 2002 325 2x4. I'm pretty sure its the pinion gear or maybe where the drive shaft goes into it. Just wondering what should I go ahead and replace once the box is opened and does the gearbox need to be completely disassembled. Any help is appreciated. Thanks in advance.

 

Pretty old stuff but thought i would try it anyway , how did it go??

 

I have a manual I can send you - I think you got a PM from me for your email address?