Join Date: Jun 2010
Location: NORTH POLE ALASKA
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!