Tuesday, May 10, 2011

HOW to disassemble rear diff on a 2003 grizzly 660?

You will have to remove, both CV axles, left rear shock, loosen front sway bar bolts, remove the left rear lower A arm bolts in order to slide out the bolts that hold the diff in place.
Remove the rear skid plate, The diff slides out through the back.

Here are some pics, all the bearings were in excellent shape so I didn't replace them, but the pics may help you see what your getting into.

See the disassembly diagrams/ pictures below:-------------
The pictures are bigger in size, so not seen full.To get bigger view.Right click on the image and select option "open image in new web" if the image is not seen full or its very small to see.-----------


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This image has been resized. Click this bar to view the full image. The original image is sized 764x1023.

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This image has been resized. Click this bar to view the full image. The original image is sized 764x1023.

This image has been resized. Click this bar to view the full image. The original image is sized 764x1023.

This image has been resized. Click this bar to view the full image. The original image is sized 764x1023.

This image has been resized. Click this bar to view the full image. The original image is sized 764x1023.

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Gear oil after just a short ride, as you can image I thought my bearings were shot!
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After I installed new pinion housing
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The pictures are bigger in size, so not seen full.To get bigger view.Right click on the image and select option "open image in new web" if the image is not seen full or its very small to see.-----------

you will have to remove the left rear lower A arm in order to slide out the bolts that hold the diff in place.

Also, remove the rear skid plat, you will probably want to be able to get your hand up from under neither. The diff might also remove from the bottom,

You can get the replacement pinion housing online because it is cheaper and my local dealer had to order it anyways. I purchased from boatnjetski.com because they where cheapest and shipped fast.
Part # 5KM-46144-00-00
Cost $37.71


You can get a kit off of Ebay that had all the bearings and seals. It is an
All-Balls brand kit ($96 shipped).
Hey next question I pressed the pinion out off the bearing and housing but I was wondering on the pinion retaining nut, Is it regular right hand threads or reverse(left hand) threads. what did you tighten yours back with?


It's regular right hand thread. I used a flat head screw driver and a hammer to get the nut off and tighten it.There is a special socket but I didn't have it. Just make sure you get it tight when you put it back together. By the way I have personally had great luck with all balls wheel bearings.

There should be something called a circlip that holds the axle in. When you want to remove the axle you take things apart and jerk the axle out of the diff. Sometimes this can happen while riding. It can't be put back in without disconnecting everything else first. You will probably need to replace the seal and the circlip. You should be able to easily do this yourself. Take it apart, replace the seal and circlip and jam the axle back in.

On the end of the axle is a small clip. When you jam the axle into the diff the clip is compressed and then it expands a little on the inside. That and the rest of the suspension parts are all that holds it in. The clip is supposed to be replaced if the axle is removed, so maybe once it pulls out on it's own it won't stay in without the new clip. I assume that you have disconnected the A arms and everything before trying to shove it back in. I don't think it would be easy to get it all the way in unless it was free to move. If your CV joint was binding I would think it would make noise while turning. The axle is a pretty expensive place to start. You could replace the clip and give it a try. You could take the CV joints apart, clean them, inspect them, re-grease them and replace the clip for a lot less than the axle. When I had a seal go bad the dealer suggested that maybe the axle had pulled out causing the seal to be damaged. He said it was something that sometimes happened and did not suggest I replace the axle or CV joints. It would also be a good idea to replace the seal just to be safe.

the axle should slide in / out on the inner cv cup. this allows the suspension to travel. if it dosn't slide freely it will possibly pop out. check to make sure it moves before you spend any money. i've had mine out several times and haven't had to replace the o ring.