Need help!!! Axles keep popping out !!! - Yamaha Rhino Forums - Yamaha UTV Forum
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post #1 of 54 (permalink) Old 04-16-2009, 11:45 PM Thread Starter
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Need help!!! Axles keep popping out !!!

I need some help on this one guys, i have a lonestar mid travel kit with i shock f-18's. my problem is that the axle keeps popping oout from the pumpkin or the diffrential. but it is not the axle or the CV joint it is the carrier that the CV sits in the green carrier on the driver side. happend again tonight, i just put the pumpkin back together changed all the seals and the fluids, ( was doing it before) i put new c-clips on both sides. and after a half hour of riding i am 3-wheel drive. look back and it has pulled out from the DIff... what am i doing wrong ???
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post #2 of 54 (permalink) Old 04-16-2009, 11:53 PM
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did it start happening after you changed something? stock cv's with what axle shafts?

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post #3 of 54 (permalink) Old 04-16-2009, 11:55 PM Thread Starter
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it happend when i broke that axle, and CV joint. so i thought maybe it was the wrong size but it measures right....but i think it might of broke in te first place because i put the hubs on up side down....stock cvs with lone star mid trael axles

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post #4 of 54 (permalink) Old 04-17-2009, 09:03 AM
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I think you got the wrong side shaft and it's just a hair to short, a 16th of an inch difference and it will pull out.

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post #5 of 54 (permalink) Old 04-17-2009, 11:19 AM Thread Starter
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That is what i thought. looks like i am going to pull it out and measure it again. i thought it was the right lenth when i put it in i measured it...this sucks...
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post #6 of 54 (permalink) Old 04-17-2009, 12:07 PM
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post #7 of 54 (permalink) Old 04-17-2009, 12:20 PM
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Maybe i can help.

Make sure your spindles are positioned correctly. The axle and cv joint need to be closer to the bottom of the car (you would think it would make sense to be the other way, but its not).

Also, here are the lengths of what the axle shafts are for the rear end for our +3 kits. This is total length, end to end. only way to measure it, is to pull them out of the cv joints completely

05-07 Years. Driver side= 19.38" Passenger side= 20.60"

If you have an 08 or newer: Driver side= 18.97" Pass side= 20.93"

Also, i would double check the length of your rear shocks. The longest they can be when fully extended are 15.47" eye to eye. If they are longer, the cv will start to go beyond its max angle, and damage will result.

If everything is correct.. i would suspect that possibly the balls, cv cage, or outer cv joint cup is damaged, and not allowing the axle to plunge in the joint. The stock cv joints don't require a lot of pressure to pop them out of the diff, so make sure the cv joint rotates, and plunges smooth. The diff side joint is the one that plunges. The outer joint is fixed.

If that all seems good, then possibly the clip that holds the joint inside the diff is damaged, bent, or not seating correctly. Or the splines on the joint or inside your diff has been damaged from it popping out or something, and not allowing the clip to perform its job.

You can also pop off the shock, and sway bar end link, and cycle the wheel through the travel, and make sure the joint doesn't want to pull out. also, spin the tire around as you move it up and down to make sure there is no binding. Keep in mind, if you go below the shock travel, it will bind, so i like to put an adjustable tie down in the shock mount eyes on the chassis and a-arm, so you know it can't go lower than that 15.47" measurement.

Feel free to give me a call if you need more help. 800-457-7223 ext 228.
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post #8 of 54 (permalink) Old 04-17-2009, 12:53 PM
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post #9 of 54 (permalink) Old 04-17-2009, 01:20 PM
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Quote:
Originally Posted by LSRGreg View Post
Maybe i can help.

Make sure your spindles are positioned correctly. The axle and cv joint need to be closer to the bottom of the car (you would think it would make sense to be the other way, but its not).

Also, here are the lengths of what the axle shafts are for the rear end for our +3 kits. This is total length, end to end. only way to measure it, is to pull them out of the cv joints completely

05-07 Years. Driver side= 19.38" Passenger side= 20.60"

If you have an 08 or newer: Driver side= 18.97" Pass side= 20.93"

Also, i would double check the length of your rear shocks. The longest they can be when fully extended are 15.47" eye to eye. If they are longer, the cv will start to go beyond its max angle, and damage will result.

If everything is correct.. i would suspect that possibly the balls, cv cage, or outer cv joint cup is damaged, and not allowing the axle to plunge in the joint. The stock cv joints don't require a lot of pressure to pop them out of the diff, so make sure the cv joint rotates, and plunges smooth. The diff side joint is the one that plunges. The outer joint is fixed.

If that all seems good, then possibly the clip that holds the joint inside the diff is damaged, bent, or not seating correctly. Or the splines on the joint or inside your diff has been damaged from it popping out or something, and not allowing the clip to perform its job.

You can also pop off the shock, and sway bar end link, and cycle the wheel through the travel, and make sure the joint doesn't want to pull out. also, spin the tire around as you move it up and down to make sure there is no binding. Keep in mind, if you go below the shock travel, it will bind, so i like to put an adjustable tie down in the shock mount eyes on the chassis and a-arm, so you know it can't go lower than that 15.47" measurement.

Feel free to give me a call if you need more help. 800-457-7223 ext 228.
Welcome Greg!

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post #10 of 54 (permalink) Old 04-17-2009, 01:46 PM
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thanks guys.. thats what i am here for. Been a member for a while now, just hard to keep up with all you guys! haha.

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