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post #1 of 22 (permalink) Old 10-17-2010, 07:21 PM Thread Starter
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front diff carnage

Started getting a popping sound in the front diff after a ride, when I opened her up today this is what I found:
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post #2 of 22 (permalink) Old 10-17-2010, 07:37 PM
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That sucks. You under warranty?
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post #3 of 22 (permalink) Old 10-17-2010, 07:40 PM
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yup looks familiar. sucks
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post #4 of 22 (permalink) Old 10-17-2010, 08:06 PM
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sorry to hear that Doug

2009 700 xtx
alum skid plates (fabrication by me)
rear bumper (fabrication by me)
front brush gard (fabrication by me)
beard seats
crow harnes (4 point)
lower tail light
epi clutch kit
soft top
full wind sheild
e brake alarm (utv crap)
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warn winch
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stage 1,2&3 clutch work by ///AIRDAM
Stock roll cage lowered 3"
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post #5 of 22 (permalink) Old 10-17-2010, 08:43 PM Thread Starter
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No warranty. I'm wondering if this is the famous shoddy pin weld I remember reading about? Guys on highlifter say theres supposed to be a needle bearing on that end of the pinion. It must have come apart and tore into the housing as things rotated. Everything else looks ok, not sure if the housing is shot or not but thats a hell of a groove wore there where the bearing is supposed to be. If the housings shot looks like she won't be fixed till after christmas, too many presents to buy! I feel like somebody shot my dog! lol
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post #6 of 22 (permalink) Old 10-18-2010, 12:34 AM
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I have been hearinga pop noise some times on my 650. I was thinking it was a CV sounds like I looking at a diff. Darn it.



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post #7 of 22 (permalink) Old 10-18-2010, 01:52 PM
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Yes there is sposed to be a brg at the end of the pinion,and yes it looks like the crosspin came out and did that damage.look at the pin that goes thru the carrier assy in your 2nd photo and you should be able to see both ends and they should be welded around the ends with a very tiny insuffcient weld.i will be putting a safety shield on my buddys soon like ive done both of mine.i will take some picts this time and post.i recommend it to everyone.it will save your cases in the event of a pin or spider/side gear failure.all the warr in the world doesnt help you 50miles from the truck!!!!
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post #8 of 22 (permalink) Old 10-18-2010, 05:04 PM Thread Starter
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Quote:
Originally Posted by team arctic View Post
Yes there is sposed to be a brg at the end of the pinion,and yes it looks like the crosspin came out and did that damage.look at the pin that goes thru the carrier assy in your 2nd photo and you should be able to see both ends and they should be welded around the ends with a very tiny insuffcient weld.i will be putting a safety shield on my buddys soon like ive done both of mine.i will take some picts this time and post.i recommend it to everyone.it will save your cases in the event of a pin or spider/side gear failure.all the warr in the world doesnt help you 50miles from the truck!!!!
You got my attention, what kinda safety shield?
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post #9 of 22 (permalink) Old 10-18-2010, 06:12 PM
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Ok,heres what ive learned the hard way.if you are hard on your stuff and have better then stock tires and you are putting it to it with the frt diff locked you can and probly will end up breaking a tooth off of a spider gear or the side gear that the non locking side axle goes into.that tooth will fall into the bottom of the case and get caught between the ring and pinion gears.this will in turn blow the cases in half.or if the cheesy weld on the spider gear cross shaft fails and the pin comes out it will cause the above formentioned damage,again destroying the case.so this is what ive done to the replacement diffs on 2 modded quads,a stk 650 xt and my 1000,and fixin to do another 1000 soon.sorry its long winded,had to work up to it.you have to remove diff and disassemble to get to the carrier assy seen in his 2nd photo.then you get some 22ga. Sheetmetal and cut a piece approx 1 3/4 x 7in.(numbers are not exact)its been awhile.you then wrap the carrier with this piece tight around the carrier so theres an 1/8 gap and secure with 2 hose clamps.then spot weld the ends to the carrier and 6 or so places around both sides.grind down the welds smooth and reassemble(you may have to trim the case slightly near the pinion brg for clearance.now the pin is trapped,as well as any gear teeth should they fail.and if it does all you havta buy is the ring gears assy for 200 buks instead of 1200 for a whole diff assy!
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post #10 of 22 (permalink) Old 10-18-2010, 06:19 PM
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I will have picts posted of this within a week with more acurate numbers.
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