[That92fourtrax]

So I just recently had a huge problem with my 92 fourtrax. It was clacking and popping and grinding somewhere in the rear. I disassembled the rear. And when it was time to take the diff off....it wouldn't come. I had to knock it off the swing arm. I got it off... I took the diff a part and it was in perfect condition. So thinking it was the u-joint. I pulled the swing arm out. Everything is perfect. I still can't find the problem but I'm putting everything back together and I'm stuck at putting the differential on. No matter what I do it just won't slide onto the little lip that sets it in the swing arm. I have to get it out my garage ASAP. Any suggestions will help...Thanks.

 

[SamUK]

If it came off it will go back on! The answer is obvious and staring you in the face!

 

[That92fourtrax]

I had to get a 2.5lb mallet and a pry bar to get it off. I’ve tried just about everything to get it on.

 

[TRXStudent]

If you heard grinding and popping in the rear then something went bad. Were you able to inspect the pinion gear and bearing? No slop?

 

[fishfiles]

Are you sure that the u-joint end of the drive shaft is still splined onto the output shaft and hasn't slide off and the u-joint is cocked in the swing arm and not on the shaft ----you can slide the boot back and check-----

 

[That92fourtrax]

I checked the pinion gear and bearing. Everything looks new. And it should because a little over a year ago I had to rebuild the differential. But I’ve been doing a lot of research. I don’t remember if I got OEM Honda parts. I think I got the cheapest rebuild kit because I didn’t have the money at the time. But anyways. If I put a knockoff aftermarket parts in the rear differential... I might have to put some shims in. Is that a possibility? I just don’t understand how everything was working perfectly until last month.

 

[That92fourtrax]

I checked the pinion gear and bearing. Everything looks new. And it should because a little over a year ago I had to rebuild the differential. But I’ve been doing a lot of research. I don’t remember if I got OEM Honda parts. I think I got the cheapest rebuild kit because I didn’t have the money at the time. But anyways. If I put a knockoff aftermarket parts in the rear differential... I might have to put some shims in. Is that a possibility? I just don’t understand how everything was working perfectly until last month.

I think it’s just binding somewhere in the differential. Because there aren’t any chips or missing teeth. But that doesn’t necessarily mean that there shouldn’t be any

 

[TRXStudent]

There are shims on each side of the ring gear. If those weren't installed then the pinion and ring gears won't be spaced properly. I've had situations where I had to really look hard for the shims, because they were hidden by nasty gunk or something, but I knew that there would be some. Shims are easy to miss if you over look them. I would take some time to inspect the splines inside the ring gear, where the axle grabs the ring gear. Dirt and water can get in there, and wear down the splines. Then the teeth will start skipping, and make alot of noise. That may be your mystery problem, as you've said your gears are all good.

 

[That92fourtrax]

Thank you. I’ll open it back up and inspect it