Replacing Everthing...well At Least A Lot Of It!

[mudsportsman05]

Alright everyone, I am finally done with this semester of shool, and I get to go home and work on my atv. I have all of the parts already and now all I have to do is install them all. I am looking for Tips on how to do everything. I have to do all of this in less then 5 days, so hopefully everything comes out and goes in easily.
I am replacing:
2 front axles
Cage in the front Diff.
Front springs
Ball Joints
Wheel Bearings
and maybe Brakes (Big_T is helping me figure out what i need to do.)

BALL JOINTS:
Whats the easiest way to get the old ones out?

I know I need to put the ball joints and the wheel bearings in the freezer. How long, does it matter?

I also have to heat up the strut to put the cold ball joint in it. WIll a regular propane torch work? How hot are we talking?

When I go to put them in, DO I need to hit them in with a hammer, Or will they slide right in?



As for the front diff:
I need to knock the pin out of the front drive shaft correct? DO I use a flat or round nosed punch? Does it matter which way I knock it out?

I then unbolt the diff. from the bottom of the bike correct?

Also, when I have the front strut and all of that off, will the springs just pull of, or are they bolted in?

ANything else?
ANytips are appreciated for installing or removing any of it..
Thanks guys and gals.

[Rubberdown]

I pulled my front diff out on my 04.5, what a pain in the ass, if I remember correctly, I had to unbolt the entire front rack and it almost fell on the dang floor (those winches are frikkin heavy). Other than that, a round punch should work fine to knock out the pin, I dont think it matter what way you push it. Then ya, just pull the mounting bolts and out it comes.

Ball joints and bearings, leave them in the freezer over night, or at least a few hours, but be carefull with the torch, too hot and that aluminum will puddle up easy. I used a little soldering torch for the ball joints and a heat gun for the wheel bearings, just because thats what I had for each of them when and where I did them. they both worked great, but be sure to get everything lined up square before you try to slide it into place otherwise it will bind and get stuck real quick.

For the spring change, just look at my sportsman front lift kit install, it pretty much covers everything since its no different than taking the stock springs off and putting them on when you install my lift kit.

To pull your axles, a good tug or jerk on the axle usually gets the fronts out, but soimetimes a slide hammer is needed, but heres my idea I have thought up for pulling mine out when I get the chance.
I'm going to have someone hold the ATV good and solid for me, then I will put a sling or tree strap around the axle shaft sinched up good and tight. Then I will put the other end of the sling or tree strap through the center hole of a 50 pound plate (ya, i got about 6 of them in the basement LOL) and put something on the opposide side of the plate to tie the sling to. Then with slack in the sling, I'm gonna jerk the 50 pound plate away from the machine as hard as I can, and I can almost picture me going flying across the room till I run into something and drop the plate on my foot, but I am pretty sure it will be enough instant pulling force to jerk that sum-bitch right out.

watch you think????

[mudsportsman05]

Thanks for the info. AS for the 50lb weight, I will leave that up to you and hopefully something will stop your fall :rip:lol

WHen you say have everything ready, when I use the torch because it the strut will bind up, what exactly do you mean by this?
I dont rreally want to use the torch, is there any other way?

Also, do I put the grease in the struth for the ball joint, before I put the new ball joint in or after I already have it in?

[Rubberdown]

make sure it is lined up good and straight because if you try to fit a press fit like this and you are off a little bit and how square or stright you are lined up, it will go in a little bit and get stuck, then it will be a real bitch to get out.

You can use the tourch, but dont blast the heat directly onto the aluminum parts as it WILL puddle or melt them. Use a heat gun if you know anyone that has one.

Grease them once they are installed.