Jimbeamrye
.060 Over
I wanted to change out the rear end oil last night. After draining old oil out, I put the drain bolt/plug back in and went to tighten it down, and it snapped right off about a 1/16" in the hole. I tried endlessly with a small screw driver to turn it back out, but when the head came off, it rounded some threads deep in the hole. Let me tell you what a deep, sick feeling you get in your stomach when you know its about to get real complicated un-doing something so stupid as over-tightning a weakend bolt that has been drilled out to put a magnet in it. Hind sight is always 20-20 I'd say, cause in the manual it clearly says to only tighten that plug to 15 nm.
I sat there just looking at the bevel box(rear end) for 30 minutes hoping to have a bright idea about how to resolve this problem. I thought about drilling a small hole into the center of the bolt and using an easy-out, but there was only that magnet to drill into. There was ONLY one way to get that broken bolt out and it was gonna require that I disassamble the entire bevel box.
You have to take the rear tire completely off first, then I flipped to the page in the manual that says "Bevel Box Removal" I actually was happy to see the details on how to remove it....at first! Then I saw the dreaded Warning box in the manual that says this: DO NOT DISASSEMBLE THE BEVEL BOX" "NO USER SERVICABLE PARTS INSIDE" "Disassembling the bevel box could result in rear end lock-up at speed and cause wreck!"
Well let me tell you, there was NO other way to get that busted bolt out without taking that friggin bevel box apart. I took it apart, very carefully, making sure that I marked the exact teeth where the Ring and Pinion met so I could put it back in the same spot. I got the bolt out, and started re-assembling it all back together, and it actually went well. I replaced the bolt with a new one. Here is its size(M10 X 1.50 pitch"coarse")
The only thing that has me concerned was when I went to slide the bevel box back onto the driveshaft, I had a hard time getting the driveshaft held up to get it to slide back into the coupler. It finallywent in and I torqued it down according to the manual in two stages. But after all was put back on and rear tire attached and tightend, I hear a clunk noise when I spin the tire back and forth? It only does it when I change the direction of the tire. Is that normal?
Anyone else here ever took the bevel box apart, or removed the box from the driveshaft and could tell me if its normal to have the driveshaft just lay down in the tube its inside? Any info on this subject welcomed!
I sat there just looking at the bevel box(rear end) for 30 minutes hoping to have a bright idea about how to resolve this problem. I thought about drilling a small hole into the center of the bolt and using an easy-out, but there was only that magnet to drill into. There was ONLY one way to get that broken bolt out and it was gonna require that I disassamble the entire bevel box.
You have to take the rear tire completely off first, then I flipped to the page in the manual that says "Bevel Box Removal" I actually was happy to see the details on how to remove it....at first! Then I saw the dreaded Warning box in the manual that says this: DO NOT DISASSEMBLE THE BEVEL BOX" "NO USER SERVICABLE PARTS INSIDE" "Disassembling the bevel box could result in rear end lock-up at speed and cause wreck!"
Well let me tell you, there was NO other way to get that busted bolt out without taking that friggin bevel box apart. I took it apart, very carefully, making sure that I marked the exact teeth where the Ring and Pinion met so I could put it back in the same spot. I got the bolt out, and started re-assembling it all back together, and it actually went well. I replaced the bolt with a new one. Here is its size(M10 X 1.50 pitch"coarse")
The only thing that has me concerned was when I went to slide the bevel box back onto the driveshaft, I had a hard time getting the driveshaft held up to get it to slide back into the coupler. It finallywent in and I torqued it down according to the manual in two stages. But after all was put back on and rear tire attached and tightend, I hear a clunk noise when I spin the tire back and forth? It only does it when I change the direction of the tire. Is that normal?
Anyone else here ever took the bevel box apart, or removed the box from the driveshaft and could tell me if its normal to have the driveshaft just lay down in the tube its inside? Any info on this subject welcomed!