[harpes620]

Bought this 93 300 for my sons birthday and we dont have much $. Its starting to pop occasionally from the rear end so I figure the pinion is going to need replaced but we just cant afford it. I am hoping its early enough to just change out the axle bearings but Im not sure how to do that. I figure I can just tear into and probably figure it out but if someone knows how I would appreciate it. Also is there anyway to tighten up the ring and pinion or something that will last a while without spending big bucks. There was no metal when I drained the fluid but it was milky as heck. I appreciate your help.
Thanks

 

[Fourtrax]

Welcome to the forums! Well you are in luck. You came to the right place for help. There are alot of VERY knowledgeable people here that can answer your question. Bad news is.. I'm not one of them. LOL But sit tight some one will have an answer for you in no time!

 

[shadetree]

the good news is..i'm one of them..the bad news..there is no cheap way to fix a rear diff !!!..lol..sorry..but..i'm affraid thier isn't anyway to cheaply fix a rear diff..now..if your ring gear..and pinion gear are ok..as in..not striped..then your off to a good cheap start...first off..you will need two very important tools to remove the pinion gear..now..if you got an old drive shaft..and some sqaure tubbing..and a wire welder...then you just saved around 300 or 400 bucks or more !!!...now..first thing you want to do is..remove the rear diff from the bike..after you get it off..remove the pinion/drive shaft oil seal....now comes the fun part !!!..lmao..if you got all of the parts handy i listed above..lets begin shall we ?..take a flat piece of metal..big enough to cover the pinion mount studs..say..about 1/2 inch all the way around..lay the metal flat on a table or bench..set the pinion end down with the studs on top of the metal..trace out the studs onto the metal...drill those out..if you got a old drive shaft laying around..cut off the end that mates to the diff pinion spline..try to cut it off where it's hollow...now here is where it gets tricky from here on out.after you have drilled the mounting studs out..and they will sit down onto the studs..place the drive shaft end that you cut off..right abover the pinion spline..try to get it as close as center of it as posb !!!..now..if you can get someone to torch that out..after you mark it..place the flat metal back down over the pinion studs..hopefully your hole you cut out..will kinda be center to your pinion shaft spline...with the drive shaft end that you cut off..place it on the pinion shaft..hopefully it fits down in the hole you cut out..now..weld it to the the flat metal..going around the drive shaft end..let it cool...if all goes well..you just made yourself a 300 tool !..after it has cooled..place it on your pinion shaft..take a socket to remove the nut on the end of your pinion off..slide everything off..now..with a piece of square tubbing....1 1/2 x 1 1/2 and a pipe wrench..one with flat jaws works best..unscrew the lock nut out..it will be kinda tight..but..it will come out..once you get that out..with a flat bladed screw driver..put the tip between the pinion head gear and the needle bearing..twist the screw driver until you push the pinion gear out some..after you get it to move alittle..you can tap it out with a punch...this is the easy part..lol..now comes the hard part..if your needle bearing is shot..and most are..it needs to be replaced..this needle bearing has a small c-clip holding it in..and it's a real pain to get out..but..it can be done !!..and this needle bearing will not come out..without getting the clip out !!!..if you can get the end of the clip to move to the center of the small hole..work as much as you can into the hole..with a very small screw driver...get under the end of it..pry it up..slowly work the clip out.bending it up as you do this..after you get the clip out..the bearing will knock out fairly easy...after you get all that done..your almost home free..thats that hardest part of these..the rest is just a matter of new bearings and new seals....oh..sorry for the long post everyone..but..there is no short version to over hauling a rear diff .

 

[Helmut]

Welcome to the forums. You can also make that lock nut tool instead of using the square tubing. Here is a link that shows you how.

ATV Nation - General Tips - Honda Lock Nut Tool

 

[Helmut]

Also, here is some more useful information I found on the High Lifter website. This will help you to understand the tools that Shadetree mentioned and will help you understand how to make and use them.

Honda Mechanic posted this:

These are the Honda rear end tools ..
Imageshack - copyofdscn3673ih0.jpg - Uploaded by Imageshack user
This is the rear end with ring gear removed..
Imageshack - copyofdscn3672os1.jpg - Uploaded by Imageshack user
Pop out the seal..
Imageshack - copyofdscn3674nk8.jpg - Uploaded by Imageshack user
Remove the large retainer nut..
Imageshack - copyofdscn3675ww8.jpg - Uploaded by Imageshack user
Imageshack - copyofdscn3681cs5.jpg - Uploaded by Imageshack user
Using the holder remove the pinion nut ..
Imageshack - copyofdscn3676nz3.jpg - Uploaded by Imageshack user
Imageshack - copyofdscn3677gs3.jpg - Uploaded by Imageshack user
Then pull the pinion ..
Imageshack - copyofdscn3683it9.jpg - Uploaded by Imageshack user
Imageshack - copyofdscn3684eq5.jpg - Uploaded by Imageshack user
The small pinion bearing comes out by working the retainer ring to the hole
and bending the tip up and pulling it out with needle nose plyers or needle
nose vice grips..The hole can be just seen thru the dirt..
Imageshack - copyofdscn3686el7.jpg - Uploaded by Imageshack user
Imageshack - copyofdscn3685fc7.jpg - Uploaded by Imageshack user
This rear end had All Balls rear end kit installed..
Imageshack - copyofdscn3687gt1.jpg - Uploaded by Imageshack user

 

[shadetree]

Welcome to the forums. You can also make that lock nut tool instead of using the square tubing. Here is a link that shows you how.

ATV Nation - General Tips - Honda Lock Nut Tool

lmfao..geee helmut..i think were chasing each others answer here..lmfao..that..or one of us is slow at typping !..lol.

 

[Helmut]

If the pinion and ring gear aren't too bad, you might get away with just putting in new axle bearings and seals. How long they will last will depend on the condition of the ring and pinion gears.

 

[Helmut]

Welcome to the forums. You can also make that lock nut tool instead of using the square tubing. Here is a link that shows you how.

ATV Nation - General Tips - Honda Lock Nut Tool

lmfao..geee helmut..i think were chasing each others answer here..lmfao..that..or one of us is slow at typping !..lol.

Yeah, that happens to me all the time. I will be typing an answer and then when I click on "Submit Reply", someone else will already have said the same thing I was going to say. Oh well, it doesn't matter as long as they get the answer. LOL.

 

[shadetree]

Welcome to the forums. You can also make that lock nut tool instead of using the square tubing. Here is a link that shows you how.

ATV Nation - General Tips - Honda Lock Nut Tool

lmfao..geee helmut..i think were chasing each others answer here..lmfao..that..or one of us is slow at typping !..lol.

Yeah, that happens to me all the time. I will be typing an answer and then when I click on "Submit Reply", someone else will already have said the same thing I was going to say. Oh well, it doesn't matter as long as they get the answer. LOL.

yep..oh..and we never did tell him to check to see what condition the rear drive axle was in ???..if the splines are stripped..there is no cheap or easy way to fix that part !!..lol

 

[Helmut]

lmfao..geee helmut..i think were chasing each others answer here..lmfao..that..or one of us is slow at typping !..lol.

Yeah, that happens to me all the time. I will be typing an answer and then when I click on "Submit Reply", someone else will already have said the same thing I was going to say. Oh well, it doesn't matter as long as they get the answer. LOL.

yep..oh..and we never did tell him to check to see what condition the rear drive axle was in ???..if the splines are stripped..there is no cheap or easy way to fix that part !!..lol

Yeah, unless it's just the hub splines, you can weld those temporarily. If it's the main drive splines, then there's no way to fix that. I welded one for a guy once, but I wouldn't recommend it and it's real hard to do, because of the seals. If the splines on the ring gear side are worn and the splines on the brake hub side are in good shape, then you can flip the axle and get by for a while. But it's best to just by a new axle. I think an axle is about $100-$110 at the Honda dealer, but if you buy a new axle, it's best to go ahead and buy new hubs, too. They're about $35-$40 apiece at the dealer. You might be able to find the axle and hubs a little cheaper somewhere else. I'm not sure.

 

[shadetree]

Yeah, that happens to me all the time. I will be typing an answer and then when I click on "Submit Reply", someone else will already have said the same thing I was going to say. Oh well, it doesn't matter as long as they get the answer. LOL.

yep..oh..and we never did tell him to check to see what condition the rear drive axle was in ???..if the splines are stripped..there is no cheap or easy way to fix that part !!..lol

Yeah, unless it's just the hub splines, you can weld those temporarily. If it's the main drive splines, then there's no way to fix that. I welded one for a guy once, but I wouldn't recommend it and it's real hard to do, because of the seals. If the splines on the ring gear side are worn and the splines on the brake hub side are in good shape, then you can flip the axle and get by for a while. But it's best to just by a new axle. I think an axle is about $100-$110 at the Honda dealer, but if you buy a new axle, it's best to go ahead and buy new hubs, too. They're about $35-$40 apiece at the dealer. You might be able to find the axle and hubs a little cheaper somewhere else. I'm not sure.

100 to 110 for an axle ??..dang..what dealer you stealing from ??..lmfao..the axle on my trx350d foreman is close to 300 bucks just for the axle !!..lol

 

[Helmut]

yep..oh..and we never did tell him to check to see what condition the rear drive axle was in ???..if the splines are stripped..there is no cheap or easy way to fix that part !!..lol

Yeah, unless it's just the hub splines, you can weld those temporarily. If it's the main drive splines, then there's no way to fix that. I welded one for a guy once, but I wouldn't recommend it and it's real hard to do, because of the seals. If the splines on the ring gear side are worn and the splines on the brake hub side are in good shape, then you can flip the axle and get by for a while. But it's best to just by a new axle. I think an axle is about $100-$110 at the Honda dealer, but if you buy a new axle, it's best to go ahead and buy new hubs, too. They're about $35-$40 apiece at the dealer. You might be able to find the axle and hubs a little cheaper somewhere else. I'm not sure.

100 to 110 for an axle ??..dang..what dealer you stealing from ??..lmfao..the axle on my trx350d foreman is close to 300 bucks just for the axle !!..lol

Yeah, I just looked them up. For the 300, the axle is $169 and for the 350 4X4, the rear axle is $265. I believe they've went up on the 300, because I'm pretty sure I paid about $110 for the last one I bought. It's been a while though.

 

[shadetree]

Yeah, unless it's just the hub splines, you can weld those temporarily. If it's the main drive splines, then there's no way to fix that. I welded one for a guy once, but I wouldn't recommend it and it's real hard to do, because of the seals. If the splines on the ring gear side are worn and the splines on the brake hub side are in good shape, then you can flip the axle and get by for a while. But it's best to just by a new axle. I think an axle is about $100-$110 at the Honda dealer, but if you buy a new axle, it's best to go ahead and buy new hubs, too. They're about $35-$40 apiece at the dealer. You might be able to find the axle and hubs a little cheaper somewhere else. I'm not sure.

100 to 110 for an axle ??..dang..what dealer you stealing from ??..lmfao..the axle on my trx350d foreman is close to 300 bucks just for the axle !!..lol

Yeah, I just looked them up. For the 300, the axle is $169 and for the 350 4X4, the rear axle is $265. I believe they've went up on the 300, because I'm pretty sure I paid about $110 for the last one I bought. It's been a while though.

one of these days..i'm going to figure out a way to rebuild axle and hub splines...i know there is some great money making to be made from it..and i've got a good idea on how to do it..it's just a matter of time..lol..i've got it in the making so to speak..i guess when you work with these alot..you kinda figure things out as you go..anyway..like i said..i've got an idea on how to do it..it's just a matter of will it work..and for how long ??..lol.

 

[Helmut]

100 to 110 for an axle ??..dang..what dealer you stealing from ??..lmfao..the axle on my trx350d foreman is close to 300 bucks just for the axle !!..lol

Yeah, I just looked them up. For the 300, the axle is $169 and for the 350 4X4, the rear axle is $265. I believe they've went up on the 300, because I'm pretty sure I paid about $110 for the last one I bought. It's been a while though.

one of these days..i'm going to figure out a way to rebuild axle and hub splines...i know there is some great money making to be made from it..and i've got a good idea on how to do it..it's just a matter of time..lol..i've got it in the making so to speak..i guess when you work with these alot..you kinda figure things out as you go..anyway..like i said..i've got an idea on how to do it..it's just a matter of will it work..and for how long ??..lol.

Good luck on that. That would be hard to do.

 

[shadetree]

Yeah, I just looked them up. For the 300, the axle is $169 and for the 350 4X4, the rear axle is $265. I believe they've went up on the 300, because I'm pretty sure I paid about $110 for the last one I bought. It's been a while though.

one of these days..i'm going to figure out a way to rebuild axle and hub splines...i know there is some great money making to be made from it..and i've got a good idea on how to do it..it's just a matter of time..lol..i've got it in the making so to speak..i guess when you work with these alot..you kinda figure things out as you go..anyway..like i said..i've got an idea on how to do it..it's just a matter of will it work..and for how long ??..lol.

Good luck on that. That would be hard to do.

nah..it's not hard to do..it's just a matter of holding up !..lol..i'd tell ya what my idea is..but..then i'd see you taking all my money making away..lmfaooo

 

[Helmut]

one of these days..i'm going to figure out a way to rebuild axle and hub splines...i know there is some great money making to be made from it..and i've got a good idea on how to do it..it's just a matter of time..lol..i've got it in the making so to speak..i guess when you work with these alot..you kinda figure things out as you go..anyway..like i said..i've got an idea on how to do it..it's just a matter of will it work..and for how long ??..lol.

Good luck on that. That would be hard to do.

nah..it's not hard to do..it's just a matter of holding up !..lol..i'd tell ya what my idea is..but..then i'd see you taking all my money making away..lmfaooo

How do they repair those two-piece driveshafts that have the splines, like a Bronco has? I had some rebuilt once, and they teflon coated the spines.

 

[shadetree]

Good luck on that. That would be hard to do.

nah..it's not hard to do..it's just a matter of holding up !..lol..i'd tell ya what my idea is..but..then i'd see you taking all my money making away..lmfaooo

How do they repair those two-piece driveshafts that have the splines, like a Bronco has? I had some rebuilt once, and they teflon coated the spines.

not sure on that..but..i'll tell you how i'd do the splines on axles an hubs..seeing how your begging to know !!..lmfao..with a brazing rod..and a known good ring gear and a torch..center the ring gear right near the bad/low spots..take the brazing rod and torch..melt the rod in the bad spot..then quickly work the ring gear back and forth over the melted braze..and it goes pretty good with 2 ppl..as one can move the ring gear..and the other work the rod an torch...like i said though..i'm not sure how well it will hold up..but..it's a very cheap fix..beats buying a new axle or hub....now..if i see your sign..saying you repair these..with my advice..i'm gonna come by your house..and throw rocks at it !!!..lmfao.

 

[Helmut]

nah..it's not hard to do..it's just a matter of holding up !..lol..i'd tell ya what my idea is..but..then i'd see you taking all my money making away..lmfaooo

How do they repair those two-piece driveshafts that have the splines, like a Bronco has? I had some rebuilt once, and they teflon coated the spines.

not sure on that..but..i'll tell you how i'd do the splines on axles an hubs..seeing how your begging to know !!..lmfao..with a brazing rod..and a known good ring gear and a torch..center the ring gear right near the bad/low spots..take the brazing rod and torch..melt the rod in the bad spot..then quickly work the ring gear back and forth over the melted braze..and it goes pretty good with 2 ppl..as one can move the ring gear..and the other work the rod an torch...like i said though..i'm not sure how well it will hold up..but..it's a very cheap fix..beats buying a new axle or hub....now..if i see your sign..saying you repair these..with my advice..i'm gonna come by your house..and throw rocks at it !!!..lmfao.

Well, I'm off to get me some brazing rods. JK. Let me know how it goes, though, if you try it.