Posted by jeffdeq
on August 21, 2009, 9:41 pm, in reply to "Won't go in gear unless diff lock is on...."
VIP Member
Yes, you most certainly have a broken axle. Here are my broken axle pictures and information links.
http://members7.boardhost.com/KazumaMammoth/msg/1234493955.html
http://members7.boardhost.com/KazumaMammoth/msg/1232252749.html
http://members7.boardhost.com/KazumaMammoth/msg/1232341487.html
http://members7.boardhost.com/KazumaMammoth/msg/1232433316.html
Put her on jackstands to remove the rear differential assembly. The left rear axle will be broken at the bearings. You can verify this by the wobbly left rear wheel. You only need to pull the left axle tube from the differential to replace just the left axle. However, you will find that the two axle bearings are bad. That is what helped caused the the failure of the axle besides the fact that the axle construction is a poor design. Since you need to replace those two bearings and the axle you need to keep in mind that the same thing may happen on the right side at some time in the future. My photos to my link should also show where I modified my axles to strengthen them. I also employed Aaron's axle hub modification in order to install double lipped seals to protect the new bearings. I also installed his clutch modification and new belt.
You can easily do this job if you wish but this is a straight forward repair for any mechanic shop. I was able to do all the work myself except for the machine shop work.
I also installed new brake disc pads upon reassembly. The Polaris brake pads are better than the Kazuma pads. However you have to ream out the square holes for easier installation.
If you encounter a problem just post a question.
Jeff
Camo Mammoth