[REDRIDER]

It took a while but I have my first real break on my Z800. My fault, little too much liquid courage where I should have just winched out. 4x4 diff locked trying to get out of a river bank launched it straight up a 4 foot bank, didn't make it out and with the wheels spinning as it came down I lost the right rear inner CV. I think I might have broken something in the front diff too, hard to tell, 4x4 was still working but I don't think the right front was turning in lock. Heard some snapping sounds but it drove home fine at 20mph. Put the front tired in the air in 4x4 unlocked. the left front when turning would spin the right front the other way, like it should.. but the right front I could get to turn freely without the other side turning... When I put it in locked both fronts did lock though kinda strange.

[NMKawierider]

That's too bad..sorry. At least the engine is still OK.

[REDRIDER]

eh, it was bound to happen lol. Tell you what I had my buddy scared coming home that night and he drives through those trails like a maniac (I feel), very tight quarters. I don't know the trails well so it was like a rally cross deal he would tell me the turns coming up. He said "I'm not telling my wife about this. You could not have driven through those trails any faster". I think I could have gone faster if I knew the trails but my machine it set up so soft and loose it feels scary swaying around the corners but she stays on all fours. get they weight swinging into the corner and you can tear ass through it drifting.
I think I saw someone post that all the diff parts are available so if I broke a spider gear and I can get it I figure it should be an easy fix and not need the whole diff hopefully.

[NMKawierider]

Long as the case is OK, the rest are pretty cheap. Odd about the CV joint though...

[REDRIDER]

Long as the case is OK, the rest are pretty cheap. Odd about the CV joint though...

Yea, there is nothing there, not even contact. I can grab the shaft and move it around and it hits nothing solid boot is still intact too. I saw no oil leaking and no crack on a quick visual inspection. I guess I'll start taking it apart this week.

[NMKawierider]

Might as well take lots of progress pics and do a thread on it. This stuff happens and I'm sure people would like to see it.

[Diver]

This will be a very interesting thread.. Please keep us all updated

[REDRIDER]

I'll keep the post updated as I figure things out, I don't have much time during the week though I will probably wait until I get the axle shaft in the mail before I get into her

[REDRIDER]

So i got the new axle in the mail.  $140 sidebysidestuff. "Heavy duty axle" didn't feel like spending $100 more on a rhino when it was just my own fault i broke it.  Took the boot off the old axle to see what happened.  Behind the boot the shaft snapped right in two the CV is still in tact lol.  I measured the old axle .880" in the middle but where the axle snapped it tapered to .790".  I measured the new axle in the middle and it is .990". This weekend i think i am going to pull the front diff and take it apart as i feel the is something wrong in there the way it was acting. When i did over 20mph on the way home i felt something grab and pulled to the right,  then it let go and was back to normal,  also if i gassed it hard i heard a crunch. Thought it was the rear axle CV but seeing as it was a clean break now I'm thinking those issues were coming from the front diff... /sigh

[ctdls]

When you elevated the front end & what happened when you tried spinning the wheels sounds like a problem .......happens when you drink to many hill levelers 

[Diver]

Amazing how that just snapped in two. I have my brother inlaws nortrack 30hp tractor here for repairs.  The front end sheared off all the bolts that hold it on. It is 4 wheel drive with a loader. I just summed it up as junk Chinese steel bolts.. I drilled and tapped it for 5/8 fine thread #8 bolts.. and was able to pull it back together... Seems china has a problem with longevity and seem to take way to many shortcuts in stress and common sense areas IMO .

[REDRIDER]

When you elevated the front end & what happened when you tried spinning the wheels sounds like a problem .......happens when you drink to many hill levelers 

Put the front tires in the air in 4x4 unlocked. the left front when turning would spin the right front the other way, like it should.. but the right front I could get to turn freely without the other side turning... When I put it in locked both fronts did lock though kinda strange.

[REDRIDER]

Ok i have determined something broke in the front diff. In 4x4 with rear tires planted and fronts in the air if i spin the quickly by hand a random snap sound appears.  Then i got the right side to spin free without the left moving arms put it in 4x4 lock and the right still spun while the left locked.  Right axle i can pull almost all the way out too so seems the cclip is broken or maybe the end of the shaft.  Either way front diff just come out.  Who's removed it?  Do i need to remove the upper control arm or can i sneak it out between the control arms?

[REDRIDER]

Ok, I do have to remove the upper control arm to get the diff out. Pain in the ass since I have an aftermarket front bumper because that bolt is too long and I don't feel like removing that bumper as it is a pita. Gonna drill a fancy hole in the bumper for the bolt to come out then make it into a recovery hook or something. I guess I'll write up a front diff r/r and teardown on the how to section when this is done

[Diver]

Looking forward for the write up.