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Discussion Starter #1
Hey guys, new to the site. I bought a '00 450 S a while back that the previous owner said needed a new rear end. Got new ring gear, axle, rear diff bearing kit, axle bearings, and swingarm bearings just to be on the safe side. I'm having a problem getting the pinion out though. I also got the special tool to get the lock nut off but I can't get past the nut that's in the collar around the pinion itself. Any suggestions on how to get this off? The service manual shows a special tool but I can't seem to find it anywhere and it probably costs an arm and a leg anyway. Tried wedging something between the case and pinion but nothing works. Also, when I took off the spacers that go on each side of the ring gear I didn't pay attention to which one went where..no idea about lash etc. I'm starting to think maybe I just need to buy a used one off Ebay and be done with it. Any suggestions? Help is appreciated.
 

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have to ask, are you SURE it was a bad rear and NOT just a bad rear axle??

reason asking is, the rear axles are known to go bad and STOP all rear drive, the weak link is actually the left rear wheel bearing/seal
water gets in, and then it makes the splines on the axle rusty, and then they wear and stop grabbing, and BOOM, NO rear drive
many folks have thought it was a bad rear end, when it wasn't? just the axle splines from water ruining them?

SO? are you sure its the rear and NOT the axle that is bad?
 

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OH and welcome to the site !

if my memory is right, I took this pic of a GOOD axle on a 400,
and am 99% sure its the same axle thats in the 450's?
in GOOD condition, should be a little over an inch dia on the splines!
maybe you can measure your's and see where your at?, or at least look at them real good and see,
as it doesn;'t take much, to make them NOT grab, and be an issue!
 

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Discussion Starter #4
Both the axle and ring gear were bad. Splines on both were worn down, diff and axle tubes were full of stuff that smelled like nuclear waste. So my question is, after ordering a new axle, new ring gear, bearings and seals for everything behind the seat, how in the heck does the nut holding the pinion come out? Not the funky lock nut, the first one you encounter. Thanks for the replies!
 
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