[Lweingart]

Hi everyone it's been a log time sense i was last active on this fourum but I'm back. My old quad is in need of some big help.

I Was at camp this weekend and my 94 fourtrax lost the power to the front wheels. I'm pretty sure its in the transfer case and it has been making a lot of clanking and grinding noise for some time now. I figured it was the CV Axel's making the nosie but now that I lost front wheel drive I'm thinking its been the transfer case the whole time.

I really need some motivation and uplifting before I say screw and give this thing away to some kid.

The Motor runs great and fires up every time. But that's about where the good ends!

No brakes at all
Pretty sure the rear axle isn't coming out (rusted in good)
Suspected transfer case shot
No idea about the front diff
Has the old style CV axles looks like an x instead of a ball.
Choke cable is froze so it idles very high
Seat is shot
Starter solenoid is shot


I know most of these things are small and eazy to fix but it all adds up.


I have a video but it's to large to upload

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[_Wilson_]

Welcome back.... If it was me... I'd hang on to it. BUT if your solid on giving it away (big mistake) the plastic looks good. All the rest can be fixed over time.

My 2 bits

 

[shadetree]

start by getting it up off all 4 wheels, have a look at the drive line. if you think the transfer case in front of the engine is the problem ?, then start by removing the center drive shaft. power comes out of the side output shaft, splits from there, goes back to rear end, as well as forward to transfer gears, then to front differential.

 

[Lweingart]

start by getting it up off all 4 wheels, have a look at the drive line. if you think the transfer case in front of the engine is the problem ?, then start by removing the center drive shaft. power comes out of the side output shaft, splits from there, goes back to rear end, as well as forward to transfer gears, then to front differential.

Hey Shade good to hear from you. I have a video of it up off all 4's and running in first gear and I can hold the front wheel and it stops and all the pooping starts.

Just don't know how to post the video. Maybe I can post it on YouTube then post the link here.

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[Lweingart]

Here is the video I took

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[shadetree]

https://youtu.be/zGbL5exSVmg

Here is the video I took

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its at the rear diff bro. sounds like you need to have a look at the rear diff. or your correct, transfer case in front of motor. at this point, you need to inspect all of your drive line.

 

[Lweingart]

https://youtu.be/zGbL5exSVmg

Here is the video I took

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its at the rear diff bro. sounds like you need to have a look at the rear diff. or your correct, transfer case in front of motor. at this point, you need to inspect all of your drive line.

Rear wheel drive works fine as far as I can tell. I can still drive it around

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[shadetree]

https://youtu.be/zGbL5exSVmg

Here is the video I took

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its at the rear diff bro. sounds like you need to have a look at the rear diff. or your correct, transfer case in front of motor. at this point, you need to inspect all of your drive line.

Rear wheel drive works fine as far as I can tell. I can still drive it around

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ok, then remove the center drive shaft from left side, inspect that and its splines, then have a look at the transfer case, and its splines going in and out to front diff.

 

[shadetree]

I have not seen hardly any front diff's on trx300's go bad, not even the transfer cases ?, this is what makes me think its at the rear diff/drive line .

 

[Lweingart]

its at the rear diff bro. sounds like you need to have a look at the rear diff. or your correct, transfer case in front of motor. at this point, you need to inspect all of your drive line.

Rear wheel drive works fine as far as I can tell. I can still drive it around



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ok, then remove the center drive shaft from left side, inspect that and its splines, then have a look at the transfer case, and its splines going in and out to front diff.

I will start to pull it apart tomorrow

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[fishfiles]

the most common thing I see is the splines on the front drive shaft coupler stripping out the spline , that could be from the spring inside the rear drive shaft coupler having clasped and letting the drive shaft move back , you might be able to see the seal ring mark is now exposed on the front coupler ---- if you think the transfer case has gone out , then drain the oil from the case into a clean container , if anything went wrong inside the case then you might see evidence of it in the oil

 

[Lweingart]

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[Lweingart]

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[shadetree]

https://youtu.be/00QQrKhHsoo

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your right !..the transfer case needs repair !. I dont see many of these go bad ?, there is always a first I guess !..lol.

 

[Lweingart]

I'm just buying one off ebay

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[fishfiles]

..that failure was preventable with some periodic checking of the oil that use to be in it , wow that is torn up !!! ---- surprised you never heard something going on for a long time

I have ragged the hell out of 300s and never had the transfer case fail on me , seen it happen to others , the reason it has never happened to me is cause I have spares , if I didn't have a spare it would have happened LOL --------- but I don't run regular oil in mine , I run super thick , clinging Lucas hub oil till it develops a leak then they get pumped with grease , same procedure for the front and rear diffs

 

[shadetree]

..that failure was preventable with some periodic checking of the oil that use to be in it , wow that is torn up !!! ---- surprised you never heard something going on for a long time

I have ragged the hell out of 300s and never had the transfer case fail on me , seen it happen to others , the reason it has never happened to me is cause I have spares , if I didn't have a spare it would have happened LOL --------- but I don't run regular oil in mine , I run super thick , clinging Lucas hub oil till it develops a leak then they get pumped with grease , same procedure for the front and rear diffs

I have seen a ton of rear diff's fail, but never seen a transfer case or the front diff's fail on trx300's ?. this is very odd to say the least !. not saying it can't happen ?, but i've never seen them tear up !. I run the same gear oil in transfer cases as I do front and rear diff's, 80w-90 gear oil. you can also run reg motor oil in them if you wanted too ?, but i've never done it, always gear oil.

 

[Lweingart]

Got everything back together tonight and she runs pretty nice. Gonna change all the fluid's tomorrow so I can run it this weekend at my camp.

I still want to pull the front diff and have it rebuilt and put in new CV axles. Also going to do the disc brake kit on the front.

Is it ok to run regular 80w- 90 gear oil in the front and rear diff and the transfer case?

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[shadetree]

Got everything back together tonight and she runs pretty nice. Gonna change all the fluid's tomorrow so I can run it this weekend at my camp.

I still want to pull the front diff and have it rebuilt and put in new CV axles. Also going to do the disc brake kit on the front.

Is it ok to run regular 80w- 90 gear oil in the front and rear diff and the transfer case?

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yep!!!!, I do it in all my trx300 builds. wont hurt a thing at all to run that gear oil all the way around .

 

[Lweingart]

Got everything back together tonight and she runs pretty nice. Gonna change all the fluid's tomorrow so I can run it this weekend at my camp.



I still want to pull the front diff and have it rebuilt and put in new CV axles. Also going to do the disc brake kit on the front.



Is it ok to run regular 80w- 90 gear oil in the front and rear diff and the transfer case?



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yep!!!!, I do it in all my trx300 builds. wont hurt a thing at all to run that gear oil all the way around .

Thanks man, I'll be getting with you soon about the front diff.

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