LockedForeman 450 4-wheel drive not working

Author
Kbug
Dirt Monster
  • Total Posts : 61
  • Reward points: 0
  • Joined: 2013/09/22 13:03:16
  • Status: offline
2013/11/07 17:03:01 (permalink)

Foreman 450 4-wheel drive not working

Since my last thread I posted, I pulled the rear end off my 2004 Foreman 450 and replaced the axle bearings. Got it back together, changed the fluids, and took it for a test drive yesterday. When I was going through a ditch, it didn't look like my 4-wheel drive was working (even though I had it in 4-wheel drive and the light indicator was lit). I was planning on going riding this Saturday, so I just jacked up the 4-wheeler to see if 4-wheel drive was working. Started it up, put it in gear and in 4-wheel drive, and both read tires spun fine. But only the front right tire spun. And when I grabbed the front right tire, I was able to hold it and keep it from spinning, despite it being in 4-wheel drive and holding the throttle down. I heard a kinda grinding/popping sound coming from the front when I was giving it gas. I know this isn't good... Last time I rode it (before I took off the rear end) everything was working fine (although I did hear a popping sound come from the front every once in a while here recently). Can someone please tell me what is the problem, or could be the problem? I've already been trying to get a group of friends to ride with this Saturday, so it's really gonna suck if I end up having to cancel.

2004 Honda Foreman 450
26" Mudlites
Moose skid plate
Snorkel
More to come...one day...
#1

10 Replies Related Threads

    xplorer 4x4
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2008/11/13 10:25:11
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/11 20:17:19 (permalink)
    sounds like cv joint on axle

    1999 foreman 400
    hmf 
    14% gr
    2000lb warn
    29.5 OL2
    #2
    jasong
    Mud Maniac
    • Total Posts : 307
    • Reward points: 0
    • Joined: 2012/05/01 07:03:08
    • Location: York SC, down a dirt road.
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/12 07:43:40 (permalink)
    Replace both joints.

    1999 Honda Foreman 400
    #3
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/13 18:04:53 (permalink)
    I discovered the problem.  The ring that holds the axle in the front differential popped off, causing the axle to slip out. Finally got the old ring dug out and a new one is in the mail.

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #4
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/16 18:00:57 (permalink)
    Now I'm having a hard time getting the axle back in with the new ring. I was told that all I have to do is put the ring in the little groove on the axle and knock the axle back in with a hammer. But how is the ring supposed to get past the gears? Since the gears on the end of the axle and the front diff fit tight with each other (like they should), how is the ring supposed to get past the gears? 

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #5
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/16 21:15:51 (permalink)
    If it would help any, I can post pics of what I'm talking about tomorrow.

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #6
    Hondaowner994
    Mud Pro
    • Total Posts : 1839
    • Reward points: 0
    • Joined: 2011/10/02 15:00:52
    • Location: Gator Country
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/16 22:46:11 (permalink)
    The ring has a gap between the the ends, when you tap the axle in the ends get pressed together allowing the axle to slide in. Once the ring gets to the groove inside of the spider gear(I think that's what it's called) the ring will expand into the groove. The groove in the gear only lets the ring expand enough so that it is halfway in the groove in the gear and halfway on the groove on the axle, holding the axle in place.

     x-Sam's Towing-x
     
    "Just try and follow me, see how well that works out for you" 
     
    If you don't have time to do it right, then you must have time to do it over.
     
    "Ol' Red"
    -1996 Honda Fourtrax 300 4x4-
    -27x10 Vamps Up Front-
    -26x12 Vamps In The Back 
    -UNI Filter-
    -Cup Holder-
    -2000LB Winch-
    -2" Lift-
    -1" Spring Spacers-
    -Fully Snorkeled-
    -Rear Brake Delete-
    -Ammo Cans-
    -Front Brake Delete-
    -Audio tube-
    -EBC Dirt Racer Clutch Kit-
    -Extra Lights-
    -Bored .40 Over-
    #7
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/17 19:29:17 (permalink)
    I know that's how it's supposed to work, but how can I get the gap in the ring closed and closed long enough to get the axle in? I've tried using pliers to close up the gap, but I couldn't get it. I've tried just putting the ring in the axle groove and knocking the axle in, but the ring sticks out so much it just pops off when I try to get it past the gear. 

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #8
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/17 19:33:09 (permalink)
    Is there any way I could take out the gear, put the axle through the gear, put the ring on the back of it, and put the gear back in?

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #9
    Hondaowner994
    Mud Pro
    • Total Posts : 1839
    • Reward points: 0
    • Joined: 2011/10/02 15:00:52
    • Location: Gator Country
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/17 21:02:11 (permalink)
    Sounds like possibly the wrong size clip or the ends are bent apart too much, try taking the clip off the axle and bending the ends together then reinstall. If that doesn't work then I'd get a smaller clip

     x-Sam's Towing-x
     
    "Just try and follow me, see how well that works out for you" 
     
    If you don't have time to do it right, then you must have time to do it over.
     
    "Ol' Red"
    -1996 Honda Fourtrax 300 4x4-
    -27x10 Vamps Up Front-
    -26x12 Vamps In The Back 
    -UNI Filter-
    -Cup Holder-
    -2000LB Winch-
    -2" Lift-
    -1" Spring Spacers-
    -Fully Snorkeled-
    -Rear Brake Delete-
    -Ammo Cans-
    -Front Brake Delete-
    -Audio tube-
    -EBC Dirt Racer Clutch Kit-
    -Extra Lights-
    -Bored .40 Over-
    #10
    Kbug
    Dirt Monster
    • Total Posts : 61
    • Reward points: 0
    • Joined: 2013/09/22 13:03:16
    • Status: offline
    Re:Foreman 450 4-wheel drive not working 2013/11/18 20:38:08 (permalink)
    It's the clip that the Honda dealer gave me. I found the reason why it wouldn't go in though. The teeth on the spider gear are a little flat on one side to help the ring go in. I got the spider gear pulled out and discovered that someone had put the gear in backwards. I got it switched around now and everything is back together.

    2004 Honda Foreman 450
    26" Mudlites
    Moose skid plate
    Snorkel
    More to come...one day...
    #11
    Jump to:
    © 2015 APG vNext Commercial Version 5.5