[Bmoore257]

I bought a used front diff from PSN and didn't realize it wouldn't have the pinion joint on it. So I need to remove my old one. Assuming the 16mm nut inside of it is holding it on, when I attempt to turn it, the whole joint spins. I put it in a vice but was scared to over tighten and it wouldn't hold it. Any tips or tricks to getting the pinion joint off?

OH its on a 98 Foreman 400!

Thanks

 

[Goober]

Sorry I don’t know how to do this. Do you have a service manual? Click the link in my sig block

 

[Bmoore257]

Sorry I don’t know how to do this. Do you have a service manual? Click the link in my sig block

Service manual refers to a special tool to hold the joint. I can't imagine many guys buying the $150 tool.

Thanks for the link though!

 

[Foreman_450]

A good grip, a torch, and a good impact should have it off in 45 seconds. Just heat the nut up inside with the torch, grab a hold with some rags and hit it with the impact.

 

[retro]

I bought a used front diff from PSN and didn't realize it wouldn't have the pinion joint on it. So I need to remove my old one. Assuming the 16mm nut inside of it is holding it on, when I attempt to turn it, the whole joint spins. I put it in a vice but was scared to over tighten and it wouldn't hold it. Any tips or tricks to getting the pinion joint off?

OH its on a 98 Foreman 400!

Thanks

I would send the front diff back to them if it arrived missing the coupler. Unless you bought it knowing that it was parted out...?

 

[Bmoore257]

I bought a used front diff from PSN and didn't realize it wouldn't have the pinion joint on it. So I need to remove my old one. Assuming the 16mm nut inside of it is holding it on, when I attempt to turn it, the whole joint spins. I put it in a vice but was scared to over tighten and it wouldn't hold it. Any tips or tricks to getting the pinion joint off?

OH its on a 98 Foreman 400!

Thanks

I would send the front diff back to them if it arrived missing the coupler. Unless you bought it knowing that it was parted out...?

I just didn’t notice it when I bought it. The picture shows it exactly as it arrived (without the joint). Odd to me though...why is the joint missing?

 

[shadetree]

I bought a used front diff from PSN and didn't realize it wouldn't have the pinion joint on it. So I need to remove my old one. Assuming the 16mm nut inside of it is holding it on, when I attempt to turn it, the whole joint spins. I put it in a vice but was scared to over tighten and it wouldn't hold it. Any tips or tricks to getting the pinion joint off?

OH its on a 98 Foreman 400!

Thanks

I would send the front diff back to them if it arrived missing the coupler. Unless you bought it knowing that it was parted out...?

I just didn’t notice it when I bought it. The picture shows it exactly as it arrived (without the joint). Odd to me though...why is the joint missing?

prob the reason it was in their hands to begin with ?, call them up, ask them if they will let you swap it out with a known full working diff ?.

 

[fishfiles]

I did it like this

 

[shadetree]

in the mean time ?, buy an air impact, large deep well impact metric socket set, and zip the nut off the pinion gear, you will need a large pipe wrench, a piece of 1 1/2 x 1 1/2 square tubbing to remove the large lock nut under the pinion oil seal ( once you pull the oil seal ) and yes..you will need a new pinion oil seal to replace this one, as you cant remove it without destroying it !. use the tubbing to get unscrew the large lock nut, tap the pinion gear out of the case, then install it in the diff you got. MAKE SURE YOU HAVE A PINION OIL SEAL ON HAND BEFORE YOU ATTEMPT THIS !. in fact, you may as well just buy a rebuild kit for your newer front diff kit seeing how your tearing it all apart ?!. the kit will come with all new oil seals, and all new bearings. you worst problem will be removing the pinion needle bearing ?, but can be done !.

 

[shadetree]

I did it like this

thats one way..lol. I must ask..why the vise grips ?, when you coulda just clamped the pinion collar in the vise just as well without the vise grips .

 

[fishfiles]

Shade , I started out with a pipe wrench and that didn't work then a chain wrench , then the vise , then the vise and a pipe wrench and it just keep slipping/spinning , then I put them little needle nose vise grips so when it started to spin it hit the grips and that little bit of extra hold was enough to get it off ------- I was putting a new collar and didn't care what happened to it and was about to weld a bar to it , the vise grips didn't do any damage to the splines -------- I would like to see a pic of the correct tool to do that job

bmoore257 ----- the splines inside the collar and the splines on the end of the drive shaft get worn and will eventually slip , have had it happen on my other 450 , and when I was doing this 450 I noticed just how worn these were , and they were about to slip , so I put a new shaft and collar , I think a lift kit causes a lot more wear on the collar and shaft ---so I know it would be hard for you to judge how worn the splines are without a new one next to it to compare or having seen it before , I might have some pics of the difference in new and worn .....

 

[Bmoore257]

I GOT IT! It sat all night with some PB Blaster and I borrowed an impact with some balls.

Thanks guys

 

[Bmoore257]

Shade , I started out with a pipe wrench and that didn't work then a chain wrench , then the vise , then the vise and a pipe wrench and it just keep slipping/spinning , then I put them little needle nose vise grips so when it started to spin it hit the grips and that little bit of extra hold was enough to get it off ------- I was putting a new collar and didn't care what happened to it and was about to weld a bar to it , the vise grips didn't do any damage to the splines -------- I would like to see a pic of the correct tool to do that job

bmoore257 ----- the splines inside the collar and the splines on the end of the drive shaft get worn and will eventually slip , have had it happen on my other 450 , and when I was doing this 450 I noticed just how worn these were , and they were about to slip , so I put a new shaft and collar , I think a lift kit causes a lot more wear on the collar and shaft ---so I know it would be hard for you to judge how worn the splines are without a new one next to it to compare or having seen it before , I might have some pics of the difference in new and worn .....

The splines do look kind of worn. I have to put the bike back together tonight but I think I’ll plan to replace the shaft and collars after hunting season.
Thanks for the “heads up”

 

[fishfiles]

That is one of them things that you can let go till it lets go , when my stripped out there was no warnings , just winnnnnng and in 2wd it was over , never knew what it was at the time , but just engaged 4x4 and rode home on the front pulling