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06 Foreman Front Differential won't disengage?

2010 Views 6 Replies 3 Participants Last post by  SamUK
Hey guys, ive got a 2006 TRX500FA with the ESP. Ive only ridden the thing a few times and I have a trip planned for the end of october, so I decided to replace the Original ball joints and tie-rods which were TOAST. Put it all back together, torqued everything to spec and lo and behold the Front differential wont unlock even when the bikes off.. Try to pull it or push it and its not wanting to go very far, maybe a foot or so before you hear a not so nice clicking sound. Im afraid to try and move it under power, since its doing this. Looked at the Right side CV Axle and it seemed to be sticking out maybe 2-3mm too far; tried pulling it and the damn thing came apart..

Tried jacking up the front end and it wont spin freely either.

That's as far as Ive gotten into it so far, but I would really like some ideas on where to go with this, oh and how to get those damn axles out.

From what I have read from very few and far between sources the Front differentials lock up is dependent on a solenoid on the front diff itself and should always unlock when it loses power..
The output shaft is spinning when we try to move the atv forward or backwards; which is supposedly a good thing?

Thanks in advanced!

1 - 4 of 7 Posts
The cup is definitely still stuck in the diff. I’m not worried about that at the moment however. The differential not spinning is what’s worrying me. Also the click is most definitely from the differential.
Well its filled with mud and rust, need a new one. What years will fit an 06?
1 - 4 of 7 Posts
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