Front gearcase removal

I am trying to remove the front gearcase to diagnose my 4x4 problem. The manual says I need a special tool to remove the locking key/pin on the front end of the transmission driveshaft where it connects to the front gearcase. Has anyone substituted a different tool in order to remove the driveshaft and front gearcase? If not, where can I get one and how much?

THANKS!!

I haven't looked at mine that close. Is it a roll pin of some sort?

Can you do it with the proper sized punch? It's just a roll pin I believe according to my service manual.

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2008 Red Gen 3, 09 "S" cage (Indian Red), Rigid 20" LED Lightbar, Raptor V2 35W HID Headlights, UTV TECH hood & grille vents, Pro Tek fuel tank armor, UMP intake, Mod Quad Speedo Bezel, Sport Roof, wide angle rear view mirror, half windshield, custom made gun racks, KMS throttle spring upgrade, alloy wheels and Skats for the dunes. Odyssey PC925 L Battery, Dunertunes stereo system, 110 db horn. Crow 4 point 3" padded harnesses. Progressive springs from Makintrax Suspension, Swaybars removed

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I found this online, take a look....$20.00 from Victor Specialty tools, just looks like a drift with a long skinny end on it!

Polaris ATV - Transmission/Gearcase/Driveline

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2008 Red Gen 3, 09 "S" cage (Indian Red), Rigid 20" LED Lightbar, Raptor V2 35W HID Headlights, UTV TECH hood & grille vents, Pro Tek fuel tank armor, UMP intake, Mod Quad Speedo Bezel, Sport Roof, wide angle rear view mirror, half windshield, custom made gun racks, KMS throttle spring upgrade, alloy wheels and Skats for the dunes. Odyssey PC925 L Battery, Dunertunes stereo system, 110 db horn. Crow 4 point 3" padded harnesses. Progressive springs from Makintrax Suspension, Swaybars removed

My Website...Check it out & sign my guestbook!

I thought it may have been threaded. If its just a pin then a punch may work. Is the pin tapered at all so it only comes out one way. Or is it a regular pin that can be tapped out from either end.

Thanks

It doesn't say in the service manual but normally a roll pin can go in or out in any direction. I would just try the easiest direction it is to get at it with a hammer and a drift if you have one that will work.

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2008 Red Gen 3, 09 "S" cage (Indian Red), Rigid 20" LED Lightbar, Raptor V2 35W HID Headlights, UTV TECH hood & grille vents, Pro Tek fuel tank armor, UMP intake, Mod Quad Speedo Bezel, Sport Roof, wide angle rear view mirror, half windshield, custom made gun racks, KMS throttle spring upgrade, alloy wheels and Skats for the dunes. Odyssey PC925 L Battery, Dunertunes stereo system, 110 db horn. Crow 4 point 3" padded harnesses. Progressive springs from Makintrax Suspension, Swaybars removed

My Website...Check it out & sign my guestbook!

Its just a normal roll pin. When I removed mine, I found something that looked to be just big enough to fit into the hole of the outside of the the front shaft ( i think it was a round file of some sort that I cut to length) and banged on it like heck using a 1/4 inch extension. It came out and I reused it using blue loctite on reasembley. I drove it out from th passanger side..

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J & T

***UPDATE***

Yes, its just a regular pin that can be tapped out with a correct size punch. Seems to be reusable with no issues. I tapped mine out from the drivers side so I dont think it matters as the pin is not tapered in any way.

***QUESTION***

Figured out why I have no 4X4. The thrust plate (I think thats what its called) was all bent up and deformed just laying between the cover plate and the armature plate. Everything else looks good included the roll cage. What purpose does the thrust plate have in engaging 4x4? Im still trying to figure out how it works. Also, I noticed in the manual digram that the coil is white and red. My coil is all white with no red at all. Not sure what that means other than possible abnormal wear and tear from the thrust plated being mangled. What would cause the thrust plated to come unseated and get all bent up?

Thanks for the help. Hope to get the parts ordered tomorrow and be back up and running before the next snow storm.

To be continued.......

You found your problem. The thrust plate must have been installed incorrectly. When you reinstall the new one use a little grease to hold it position. and follow the backlash instructions in your service manual.

.....forgot to ask.....should the armature plate be somewhat of a cone shape in regards tothe inner and outer diameters? Hope that make sense. When laying on a bench mine does not lay flat it has a slight taper to it and is somewhat cone shaped if you will. If its supposed to be flat, looks like I need a new armature plate too.

THANKS!!

Any 4x4 experts out there? I am having a hard time understandig how the front gear case angages and creates 4x4. How does the armature plate engage and what does it engage with. How do the hubs lock together? No matter what I do the pinion will not turn or enagage the hubs. Does the roller cage slide and lock into place or does the whole clutch assembly gear slide to engage the pinion gear. I have the manual and I have the case removed and opened up on the bench.

I have a feeling the previous owner may have had the case opened up before. There was no 4x4 when I bought it. When I opened up the case the thrust plate was all mangled up and just laying on the clutch assembly. Not sure how it all works so I can make snese of it to put it back together.

Help!

Thanks!

Chad

Read page 209 of your manual, This should help you understand how it works.
I belive the plate should be flat. You need to check out page 210, make shure the plate is in contact with the U-shape insert in the cover. It it is not contacting on both sides the magnetic force(or drag) on the armature plate will not be strong enough to ingauge the rollers.