[JThomsen1286]

I have a 2006 Foreman 500 4x4 and the front output shaft seal was leaking and finally got around to fixing it. A buddy came over and helped since he said he had experience with these seals. Well got the front diff moved and shaft disconnected. Got the old seal out and he cleaned the shaft up and was putting the new seal in.
Here’s the issue I got now, he somehow pushed the seal to far and into the case. Part number is 91201-HP0-A01, and had it confirmed multiple times from Partzilla and Bike Bandit that it was the correct part number.
Am I screwed and have to split the case to get the seal out? Can I get a new seal and press it in? So apparently it appears my buddy was full of sh$t. Any help would be great.

JT

 

[Garagefinds]

I have a 2006 Foreman 500 4x4 and the front output shaft seal was leaking and finally got around to fixing it. A buddy came over and helped since he said he had experience with these seals. Well got the front diff moved and shaft disconnected. Got the old seal out and he cleaned the shaft up and was putting the new seal in.
Here’s the issue I got now, he somehow pushed the seal to far and into the case. Part number is 91201-HP0-A01, and had it confirmed multiple times from Partzilla and Bike Bandit that it was the correct part number.
Am I screwed and have to split the case to get the seal out? Can I get a new seal and press it in? So apparently it appears my buddy was full of sh$t. Any help would be great.

JT

could you use the trick of using a drywall screw to pull the old one out and then just replace with a new one?

 

[JThomsen1286]

That is a good suggestion, I will give it a shot tomorrow. I’m surprised there wasn’t a lip or a stop of some sort to prevent that from happening. I searched multiple forums and only found one other but there was no answers. Thank you Garagefinds.

 

[JThomsen1286]

Was able to get it out. Don’t tell the wife but used one of her dental hygienist picks. Tried the screw technique and wasn’t able to pull it free but used the hole it created and the dental pick and was able to get enough out to use some needle nose pliers. All is good now, and know for the next seal when it gets here to be careful pressing it in.