[gone]

Recently I noticed a torn CV boot on my left front outer. Pulled it down and when I popped the axle out the inner circlip didn't come with it..it actually got pulled over or out of the groove. So..it's in there..but from the position of the spider gear's cross pin being horizontal, it likely bounced off it and fell straight down...and if so, may have fell through one of two openings in the carrier to the bottom of the case. At least that's what I can hope for as I have been in there through the axle opening with magnets and grabbers of all type trying to find and retrieve it but with no success. I have some special smaller flexible magnet retrievers coming with a 5mm head that can go farther but gut tells me two things- one, if that clip gets into any gear-set, the diff is gone so it has to be found and removed...and the other is..if it has fallen to the bottom of the case, it may find itself bound by the magnetic end of the drain plug and stay put in time. Although there is no way it can come out the drain plug hole, at least it would be captured. A third option may be  (other then complete removal and disassembly), looking at the inside when the actuator is off, there looks to be an opening into the main case area that one might be able to slip a flex magnet down into and possibly find that clip. The shame would be that I went to extra lengths to stop that actuator from leaking oil and all that would be undone..and re-done if removed...and for nothing if I can't find the clip. I do have new clips coming along with all new booted BTW. I will likely try everything possible through the axle opening and the actuator opening to find and remove it first. After that..there are few options left.

So, I put it to the community for discussion: ...what you you do if you were in my shoes!    

Try the lil magnets you ordered if no go then Drain it an see if you can flush it down with some more oil an air at least you'd see it in the drain hole hopefully an know it's there
sadly I think your looking at a removal an opening it up


I've had them come off axles before an magnet my whole machine an was lucky to find it
Thinking it went in the diff doesn't sound like your that lucky today

[2015 Z Force 800 53/Trail EPS]

Yeah it's in there. I also see where the open end of the clip ripped across the end of the axle as it came off. Sure hoping I can get it without pulling the diff though. Good idea with the air. I can make a long snout for my blower tip, put a quick 90 on the end and maybe with the oil drained I can make sure it falls all the way out of the carrier to the bottom.

I think your onto something with the actuator removed. That's probably your only way to fish it out without opening the diff.

[2015 Z Force 800 53/Trail EPS]

I think your onto something with the actuator removed. That's probably your only way to fish it out without opening the diff.

Yeah it looks like if I can get it to drop through the carrier, the left side of the opening drops down under it and plenty of room for a 5mm magnet head to get into.

I would clean all the sticky oil out of it with about 12 cans of brake cleaner. After that i would take the magnetic drain plugs out of it then turn it upside down and try to shake it out.. If that did not work i would try fishing around with the little magnets you have ordered.Last resort. Split the case. You would not be changing anything so it should be easy to do without worry of needing new shimming.

[2015 Z Force 800 53/Trail EPS]

I would clean all the sticky oil out of it with about 12 cans of brake cleaner. After that i would take the magnetic drain plugs out of it then turn it upside down and try to shake it out.. If that did not work i would try fishing around with the little magnets you have ordered.Last resort. Split the case. You would not be changing anything so it should be easy to do without worry of needing new shimming.

Thanks Ama. I am going for some BrakeKlean to do some washing-down because...update- pulled the actuator and there is no access to the lower area because of the carrier bearing. However..while on the floor I did find that half of the clip did come out with the axle..I assume..because it was just on the floor under the diff...Hmm..right under the open drain hole...funny I didn't see it before blew lots of air in and through the carrier with an extension I made with a little 90 on the end. It is almost exactly half of it which makes it just a hair over 10mm across...which will fit through the 12mm drain hole, so maybe that's where it came from. So I will try and do some flushing with the brake cleaner and chase it with some air...with and without the plug and magnet installed. Maybe get a little more lucky. As I search the internet on this issue I find that this happens more often with CFMotos then most others but usually they are in one piece...so be careful out there guys. Resist the temptation to put the hub back on the splines with the washer and nut and use it as a slide hammer as I did. Better to have patience. Here's some pics:

[2015 Z Force 800 53/Trail EPS]

Update: Blasted three cans of break cleaner through it in all carrier positions and directions with and without the magnetic drain plug in as well as blasted air in every direction and opening as well as spent hours with the magnets and come up with nothing more. So..I know the other half is in there somewhere but I think I am going to risk it and put this puppy back together and run it. Might run the bore scope back in one more time just for GP. Put the new clip on the axle and it is expanded so far out of the groove there is no way it could ever collapse-down when being bumped-out so I made a little adjustment to it. Might still have a problem but at least it has a 1/2 a chance now. No wounder so many have had issues.

Scary not knowing for sure where the other half is.Any way to glue a strong magnet to the outside in a spot that would hold the piece in a safe spot if it does starts swimming around in there?

[2015 Z Force 800 53/Trail EPS]

Scary not knowing for sure where the other half is.Any way to glue a strong magnet to the outside in a spot that would hold the piece in a safe spot if it does starts swimming around in there?

Maybe..I'll consider that. I was thinking that in several posts I read and one video I watched, the people found them all stuck to the drain plug magnet. Of course whole it can't get through the drain hole but..there is a chance a half of one just might. So I'll be looking for it on the next oil change. The scary thing is.. although there is a lot of play and sloppy clearance in the spider gears and if it got there it wouldn't probably be a problem, the ring and pinion are much tighter...and I believe the outer ring gear is right above the drain port and plug magnet...like about 1/4" above it. I think I'll put in what I use in the rear which is an 80w140. Maybe that will slow the fluid currents next to the outer case enough to not pick it up. If it does and wastes it...so be it. Maybe it's time to get that new RMax 4 1000...or Outlander    The wife would have a fit though.