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front differential seal and bearing replacement

3070 Views 5 Replies 5 Participants Last post by  Sport4x4
Has anyone replaced the seals and bearings on the front diff? After breaking the front diff open I am unable to remove the pin that holds the diff locking mechanism operated by servo motor to get to the last bearing. I looks like the pin was stamped in or something I have no idea. If anyone has removed this or replaced the front bearings and knows how to get that out please let me know. I took it to a yamaha shop and they tried to make be buy a new housing for it.
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I haven't done one but looking in the manual it says,



"NOTICE

The differential gear assembly is assembled
into a proper unit at the factory by means of
specialized equipment. Do not attempt to
disassemble this unit. Disassembly will result
in the malfunction of the unit."


It also says,


"Do not disassemble the differential motor or
remove the differential motor pinion gear.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the differential
motor terminals “1” (as shown in the illustrations).
NOTICE

• Do not use a 12 V battery to operate the differential
motor pinion gear.
• Do not connect the batteries to the differential
motor when it is installed in the differential
case.
• The differential motor should be checked
when it is removed from the differential
case."


Then it doesn't actually say how to remove the servo motor, but to assemble it it says this,


"• Differential motor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide the shift fork sliding gear “1”, which is installed
to the differential case cover, to the
right front constant velocity shaft assembly
side as shown in the illustration to put it into
the 2WD mode.
b. Connect two C-size batteries to the differential
motor terminal “2” to operate the differential
motor pinion gear “3”. Operate the
differential motor pinion gear until the mark
“a” on the differential motor pinion gear is
aligned with the mark “b” on the differential
motor case.
NOTICE

Do not use a 12 V battery to operate the differential
motor pinion gear."


Not sure if you reverse the above you may be able to remove the servo motor? Hope that helps.
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Thanks for that bit of info. However I already disassembled it all and I actually was able to get the last bearing out after knocking the middle gear out of the bearing. It allowed for the diff lock to move up and give me enough clearance to get the bearing out without having to remove the pin that the diff lock slides on. However after removing the bearing I figured out it is not the same size as the other two in the diff. It is a 16006 and the other 2 are 6006. I guess that is why the rebuild kit only comes with 3 bearing instead of 4 because yamaha wants you to have to buy the $200 other part of the housing. The bearing was only $21 on amazon. Hope this helps anyone trying to do this and save some money.
How many miles we're on yours that you had to rebuild the front diff? Or did you just break something?
I know this is an old thread but did you end up getting this done yourself? About to do the same to mine, have some water in it and I wanted to take it apart to investigate….
Michigon hasn’t visited this forum in 5 years so you probably won’t get a response.
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