front diff leak

[CatMan-do]

the jeepcats front diff leaks where the drive shaft goes into the diff. has anybody changed this seal? is it a PITA to change?

[rapidrobert]

I have my front differential out of my 650v2 rite now for resealing.
You will have to pull out the differential.
On the scale from 1 to 10 I would say that the job would rank about a 7 on the PITA Scale.
You will need to order the o-rings on the 4x4 actuator because they will be swelled out of shape and will not be able to be reused.
you will need 2 axle seals and input seal and input housing gasket. My 650v2 has a snap ring that has to be taken off after you un
bolt the housing off the differential to get the input shaft out were the seal is leaking.
before I went to the trouble of this repair I would make sure that the vent is clear and open for the front differential, all-so make sure that the fluid is not contaminated with water
this will make the seals leak.
All-so some of the cat wheelers were over filled with to much fluid at the factory and it caused the seals to leak.
Before i did any thing I would change the front differential fluid and do not overfill it. fill it slow with the check plug out until you only get a drip out of the check plug then stop filling. It holds around 8 oz. of 80w90 gear oil . Then I would clean it off and ride it and recheck it.
Then if it still leaks, I would order the parts and schedule the surgery. Good luck Rapidrobert...

[CatMan-do]

Thanks for the info..changed the dif fluid 3 times on the 500 the same way using the level hole, 32oz bottle did  f/r with 18oz left so thats 7 oz per dif. the book said Front 9.3 R 8.5 ?
any way over on Arcticchat they said to take the skid plate off ,unbolt the dif and move it forward should be able to get the shaft out that way ? will try that first and see. will let you know how it worked out

[rapidrobert]

Here is the link to the arctic cat atv service manual it may help you out.
http://www.mymowerparts.com/pdf/Arctic_Cat_ATV_Repair_and_Service_Manuals/
Rapidrobert...

[CatMan-do]

I think I have that...some place ... on here thanks

[CatMan-do]

theres two clamps on the drive shaft boot, how do I get them off with out tearing up the boot? can those clamps be used again?