Thanks for your help . Appreciated the video as I am just wiping up my hands for a break after doing the center section . Basically a few outer bearings and seals left before topping it up for a test ride ............ after I also do the swing arm bearings . See you next week when I comment on your engine tear down video as I am putting a new can , piston , rings , and valve stem seals on it . Cheers man and thanks again for the videos , makes it so much easier with a visual aid
I have always used a carbide burr to cut the snap ring and grind a slot in the bearing then drill a hole at the back of the bearing and apply a liberal amount of 5 lb sledge blows to the back.
Oh man, I’m in the same boat. This is the job I’m about to take on, not the work or repairs that I’m concerned about, it’s the getting the pinion bearing out, got a brand new axle and ring gear on the way but my pinion has some mild damage like small pits and one spot a tiny piece out of the tooth. I was going to attempt to smooth and polish the pinion gear with out remove material but may just have to buy a new one. Btw very good video man. You did awesome and very helpful.
Like I said in the video getting the pinion bearing is by far the hardest step. Nine times out of ten the bearing is bad and needs to be replaced. I have had some come out in 15 minutes and some take 2 hours to get out trying different methods.
You help me out lots when you rebuilt the Rincon engine! Thank you for that! Now I'm doing this haha I can find the info anywhere, the seal on the wheel hub, which way does it go in? Groove facing up or flat side facing up ? Thanks!
Do you have the link for the bearing kit? Great detailed video, I have the same problem with my 2007 honda forman 500. Did you replace the ring gear along with the axle shaft?
I don't remember the exact kit I used but I just picked one off eBay that was around the middle of the price range. I have had fitment issues with the cheaper kits.
Hey buddy I really appreciate your content on here very detailed ty . I was wondering if you could help me with problem I have with my 04 Honda rancher 400fa it was shifting issue I figured that out with a new throttle position censer but when I got it back together I fired it up and man it was running extremely ruff for about 30 second then died well what ever happened it made it stop firing all together do you think it might be the ecu it has me all kind frustrated can you bless me with some your great knowledge I would really appreciate it a lot ty again for your great video content
I don't replace many ecu's on these bikes. I will check the plug, coil, plug wire, handlebar killswitch, and even the rectifier on these bikes can make them not fire. The testing procedure for the ECU is pretty much check everything electrical and if everything checks out then your ECU is bad.
My 2004 Honda Rubicon 500 is making a grinding sound from the rear. I am pretty sure the sound is coming from the differential. The four-wheeler won't move in any gear. What is your opinion on it? Do I need to replace the rear differential?
Hey man really appreciate what you do I’m trying to replace the seal where the drive shaft goes into the diff. On a 2018 foreman 500 straight axel the driveshaft goes through the swing ark frame and I’m unsure how to remove it to get to the seal. Without unbolting the whole diff from the swing arm. Any help
Put mine back together but when I put the bolts in the cover and tighten down it will barley spin hand and u can tell something isn’t right…. I think The spacer on the pinion gear shaft stuck to the bearing I never put in….. gonna cost me a seal but I hope that’s what’s wrong
Replaced just the axle shaft a year and a half ago on a 2014 Foreman, same thing as this is wore in the same way. Well now something else let go last week, not sure if the axle shaft wore again, or the ring or pinion gear failed. Mechanic looking at it now, will update when I get a diagnosis
Hey man, great video. My question is: I have a 2017 Rancher with solid axle, I think the pinion has gone but I won't know until I tear it down. Does Honda use the same axle on the foreman as they do on the rancher. Basically will I run into anything different on my rancher, Thanks
Sometimes I have to break out the 3/4" impact. if you're planning on replacing your bearings and seals you can always break the torch out, heat it up real good and get it to come loose.
I bought the East lake kit also. I put it all together today. I noticed a large roller bearing in the kit the had a slot for maybe a c-clip or equivalent. Did you have an extra one of these in your kit too? Don't see any where that it would go?
It seems like there was one extra one in the kit. I have run into that before where they have one kit that fits multiple vehicles that have a few extra bearings.
@@FourwheelerDoctor Well and that's what I figured. I replaced all the ones in my rear axles and diff. Man what a job. That pinion bearing had me worried. But I get her. Thanks for the reply. Always good to hear from you.
When you hit on the gas did your rear end raise up? I have brand new socks and when I hit on the gas it will raise up a little bit in the back and when I put in reverse and hit the gas the back end would squat
This is the best video I have watched on rebuilding the rear end, im going to tackle this , this weekend and watch ur video step by step...also what diff oil do I need to use ? Where are u located may have u work on my atv ?
What is ur cost on rebuilding an 2006 honda foreman 500 4x4 ES. Diff. Just the diff, I will be mailing it to u. I have the rear disassembled juat dont have the pressure to remove the bearings.
Got a 02 foreman for free. Everything is worn-out. Rear diff was dry and full of thick rust. Seems like it has never been serviced. All brake components are seized or missing. Doesn't shift. All bearings shot and rod ends wasted. Missing some plastics. Digital dashboard completely shot.
I'm rebuilding one of those right now. Some the parts are reasonable however some are super expensive. For instance I had to get the crankshaft rebuilt on them because they're no longer available from Honda. Also some of the plastic pieces are very expensive and used stuff has been tough for me to find. They are very good four-wheelers but you would really have to dump some money in it to get it right.
More than likely it's a bad pinion bearing. It could also be your swingarm bearings. See if you swingarm has any movement side to side up by where it attaches to the front
If you just need to replace the drive shaft, you can pull the diff off like I did in the video a pull the shaft out. It takes a little patience to get the shaft to line back up with the universal joint that attaches to the motor but it can be done. If you need to replace the universal joint that attaches to the output shaft of the motor then you will have to pull the swing arm off to get it out. I don't think I have a swing arm removal video on a 500 but I think I have a video of a similar one. I will find it and post a link.
@@cindybrady7381 I would guess around 2.5 hours. Check out this video ua-cam.com/video/XgqrjHIaCI8/v-deo.html The process will be very similar to this.
@@FourwheelerDoctor so I did this tonight and didn't take long at all but I have a new problem I was going to replace a broken axle but couldn't get the ball joints to break lose I hit and hit and hit again so how do I need to do this so I can pull the hub and knuckle off to take the axle out? Thanks
No it sounds like you have two seals that have gone bad. The axle seal on the right side of the diff and the seal on the left side of the rear brake plate. They can be purchased separately from Honda but if you go with aftermarket seal kits you will probably have to purchase a axle kit as well as a differential kit.
Four wheeler Doctor i bought the kit and I opened the differential and it looks ok has no play on any bearing and seals look new but I do I have the seals for the axles I will be replacing today ..thank you for your videos it’s a lot of help
Why do they call them differentials when they are clearly spools with zero differential capacity? It looks like more frequent oil changes would have helped that.
Only vid that helped me understand all the other ones don’t show
Thanks for your help . Appreciated the video as I am just wiping up my hands for a break after doing the center section . Basically a few outer bearings and seals left before topping it up for a test ride ............ after I also do the swing arm bearings .
See you next week when I comment on your engine tear down video as I am putting a new can , piston , rings , and valve stem seals on it .
Cheers man and thanks again for the videos , makes it so much easier with a visual aid
Thanks man, gonna tackle this tomorrow. Appreciate you putting this up.
I have always used a carbide burr to cut the snap ring and grind a slot in the bearing then drill a hole at the back of the bearing and apply a liberal amount of 5 lb sledge blows to the back.
I’ve been searching for days for the part number of those three O ring the one that is on the flange that goes to the final drive shaft
Great video man
Peice of 2" square tube fits right into that inset nut on the pinion shaft
Oh man, I’m in the same boat. This is the job I’m about to take on, not the work or repairs that I’m concerned about, it’s the getting the pinion bearing out, got a brand new axle and ring gear on the way but my pinion has some mild damage like small pits and one spot a tiny piece out of the tooth. I was going to attempt to smooth and polish the pinion gear with out remove material but may just have to buy a new one. Btw very good video man. You did awesome and very helpful.
Like I said in the video getting the pinion bearing is by far the hardest step. Nine times out of ten the bearing is bad and needs to be replaced. I have had some come out in 15 minutes and some take 2 hours to get out trying different methods.
Great video
Thanks and thanks for watching
I bet you like it when they bring you a clean bike.
Oh yes and as you can imagine I get some nasty ones too
Thanks😘
You help me out lots when you rebuilt the Rincon engine! Thank you for that! Now I'm doing this haha I can find the info anywhere, the seal on the wheel hub, which way does it go in? Groove facing up or flat side facing up ? Thanks!
Do you have the link for the bearing kit? Great detailed video, I have the same problem with my 2007 honda forman 500. Did you replace the ring gear along with the axle shaft?
I don't remember the exact kit I used but I just picked one off eBay that was around the middle of the price range. I have had fitment issues with the cheaper kits.
Hey buddy I really appreciate your content on here very detailed ty . I was wondering if you could help me with problem I have with my 04 Honda rancher 400fa it was shifting issue I figured that out with a new throttle position censer but when I got it back together I fired it up and man it was running extremely ruff for about 30 second then died well what ever happened it made it stop firing all together do you think it might be the ecu it has me all kind frustrated can you bless me with some your great knowledge I would really appreciate it a lot ty again for your great video content
I don't replace many ecu's on these bikes. I will check the plug, coil, plug wire, handlebar killswitch, and even the rectifier on these bikes can make them not fire. The testing procedure for the ECU is pretty much check everything electrical and if everything checks out then your ECU is bad.
My 2004 Honda Rubicon 500 is making a grinding sound from the rear. I am pretty sure the sound is coming from the differential. The four-wheeler won't move in any gear. What is your opinion on it? Do I need to replace the rear differential?
Hey man really appreciate what you do I’m trying to replace the seal where the drive shaft goes into the diff. On a 2018 foreman 500 straight axel the driveshaft goes through the swing ark frame and I’m unsure how to remove it to get to the seal. Without unbolting the whole diff from the swing arm. Any help
The only way to get to the seal is to unbolt the diff.
Put mine back together but when I put the bolts in the cover and tighten down it will barley spin hand and u can tell something isn’t right…. I think The spacer on the pinion gear shaft stuck to the bearing I never put in….. gonna cost me a seal but I hope that’s what’s wrong
Hey got a light tick sounds like its. Coming from middle driveline. Just sometimes it dose it can u tell me what it mit be
Replaced just the axle shaft a year and a half ago on a 2014 Foreman, same thing as this is wore in the same way. Well now something else let go last week, not sure if the axle shaft wore again, or the ring or pinion gear failed. Mechanic looking at it now, will update when I get a diagnosis
Diagnosis?
@@zzzzzz...9902 Rebuilt the chunk
I don’t have the collar on the left hand side doesn’t look like one would fit in there?
What was it? Cause mines not going on drive I’m thinking it’s the drive shaft teeth gone bad
Hey man, great video. My question is: I have a 2017 Rancher with solid axle, I think the pinion has gone but I won't know until I tear it down. Does Honda use the same axle on the foreman as they do on the rancher. Basically will I run into anything different on my rancher, Thanks
It will be the exact same process and look the same as the foreman.
How did you get your left axel nut undone. I have tried a big eletric Hammerdrill and all my weight on a 2 ft breakerbar (72kg)
Sometimes I have to break out the 3/4" impact. if you're planning on replacing your bearings and seals you can always break the torch out, heat it up real good and get it to come loose.
I bought the East lake kit also. I put it all together today. I noticed a large roller bearing in the kit the had a slot for maybe a c-clip or equivalent. Did you have an extra one of these in your kit too? Don't see any where that it would go?
It seems like there was one extra one in the kit. I have run into that before where they have one kit that fits multiple vehicles that have a few extra bearings.
@@FourwheelerDoctor Well and that's what I figured. I replaced all the ones in my rear axles and diff. Man what a job. That pinion bearing had me worried. But I get her. Thanks for the reply. Always good to hear from you.
@@FourwheelerDoctor is there supposed to be play in the pinion up and down when installed in the housing
When you hit on the gas did your rear end raise up? I have brand new socks and when I hit on the gas it will raise up a little bit in the back and when I put in reverse and hit the gas the back end would squat
That’s how straight axle fourwheeler ss work
Hey how much was the kit to rebuild thanks
What did you use to clean the inside of the diff so well??
I have a parts washer to get the big stuff out and then I use brake cleaner to clean it the rest of the way.
This is the best video I have watched on rebuilding the rear end, im going to tackle this , this weekend and watch ur video step by step...also what diff oil do I need to use ? Where are u located may have u work on my atv ?
Thanks man. I just 80/90 weight gear oil in my rear ends. Also I'm located in south Carolina.
What is ur cost on rebuilding an 2006 honda foreman 500 4x4 ES. Diff. Just the diff, I will be mailing it to u. I have the rear disassembled juat dont have the pressure to remove the bearings.
Got a 02 foreman for free. Everything is worn-out. Rear diff was dry and full of thick rust. Seems like it has never been serviced. All brake components are seized or missing. Doesn't shift. All bearings shot and rod ends wasted. Missing some plastics. Digital dashboard completely shot.
I'm rebuilding one of those right now. Some the parts are reasonable however some are super expensive. For instance I had to get the crankshaft rebuilt on them because they're no longer available from Honda. Also some of the plastic pieces are very expensive and used stuff has been tough for me to find. They are very good four-wheelers but you would really have to dump some money in it to get it right.
I have a 2002 500 Rubicon making a bunch of noise and rear end shakes a bit what you think
More than likely it's a bad pinion bearing. It could also be your swingarm bearings. See if you swingarm has any movement side to side up by where it attaches to the front
Same problem happened to me I did the same thing
Hey buddy do you have any tips on replacing a rear drive shaft on a 2006 honda rubicon 500?
If you just need to replace the drive shaft, you can pull the diff off like I did in the video a pull the shaft out. It takes a little patience to get the shaft to line back up with the universal joint that attaches to the motor but it can be done. If you need to replace the universal joint that attaches to the output shaft of the motor then you will have to pull the swing arm off to get it out. I don't think I have a swing arm removal video on a 500 but I think I have a video of a similar one. I will find it and post a link.
@@FourwheelerDoctor
Thanks. That's what I was thinking but wanted to make sure there wasn't anything I was missing before I tore into it.
@@FourwheelerDoctor sorry to keep bothering you but about how long would this take if all goes well? Thanks
@@cindybrady7381 I would guess around 2.5 hours. Check out this video ua-cam.com/video/XgqrjHIaCI8/v-deo.html
The process will be very similar to this.
@@FourwheelerDoctor so I did this tonight and didn't take long at all but I have a new problem I was going to replace a broken axle but couldn't get the ball joints to break lose I hit and hit and hit again so how do I need to do this so I can pull the hub and knuckle off to take the axle out?
Thanks
I opened the brake drum up and I noticed it had oil all inside! Is that normal?
No it sounds like you have two seals that have gone bad. The axle seal on the right side of the diff and the seal on the left side of the rear brake plate. They can be purchased separately from Honda but if you go with aftermarket seal kits you will probably have to purchase a axle kit as well as a differential kit.
Four wheeler Doctor i bought the kit and I opened the differential and it looks ok has no play on any bearing and seals look new but I do I have the seals for the axles I will be replacing today ..thank you for your videos it’s a lot of help
My pinion gear does not want to come out I do not know what to do
I assume you got the star looking nut loose?
How much will something like this cost?
The bearing and seal kits usually run around $100 or a little less. And I usually figure about two and a half to three hours labor
@@FourwheelerDoctor thanks for the fast reply
By any chance are you located in texas
@@li09li09li09 nah sorry man. I'm from South Carolina.
Clean that ring gear out and shine a light on it. I bet its toasted.
Why do they call them differentials when they are clearly spools with zero differential capacity?
It looks like more frequent oil changes would have helped that.
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