06 axle keeps popping out... - Yamaha Rhino Forum - Rhino Forums.net
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post #1 of 15 (permalink) Old 02-27-2011, 12:25 AM Thread Starter
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Billy Goat
 
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06 axle keeps popping out...

I did a search and got thru 3 pages of replies and couldn't find my answer.
I have heard axle pop-outs on the rhino are fairly common.

I just bought a 2006 Rhino 660. My left rear axle keeps popping out moments into our ride. A few things that may affect this:

1)27" ITP XTRs on 14" rims.
2)NO sway bar.

Appears to have stock height, and stock width a-arms. I think the axles are stock, but don't know the difference to look at a Gorilla vs. regular axle. Actually, the shaft on the right rear looks quite shiny and I'd guess it's been replaced, but I don't know.

I noticed the circlip on the inner CV stub that snaps into the rear diff is the square cut style, not the original rounded circlip. I heard the square cuts are supposed to be better (NOT SO FAR for me!!).

My friend's '08 700 was a nightmare for axle pop outs. So I want to nip his in the bud. I don't want my riding weekends ruined because of repetitive axle pop-outs. So what can I do to stop this?

I plan to put on 25" Bighorns on 12" rims, and also put a sway bar in.

(Anybody wanna sell me their factory swaybar?)
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post #2 of 15 (permalink) Old 02-27-2011, 02:44 AM
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Try replacing the snap ring. If that doesn't work there are a few threads that explain how to bolt the 2 inner axle cups together using all thread or the right sized bolt. Then they will never come out. Just have to pull the inner cv's apart to remove the inner cups. I think a few lower grade axle replacements cut the groove for the snap ring too deep and this is where the problem lies. Also I've got a spare used stock inner cup from a 660 if you want to try that before drilling.

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post #3 of 15 (permalink) Old 02-27-2011, 06:03 AM
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https://www.rhinoforums.net/general-r...ing-axles.html

many many threads on this topic ,this link will save you some time!!!

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post #4 of 15 (permalink) Old 02-27-2011, 09:00 AM
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Make sure that you rear differential support tabs or crossbar are not broken. I seen this on a friends and brother in law's rhino
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post #5 of 15 (permalink) Old 02-27-2011, 09:45 AM Thread Starter
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thanks, i'll have a look at the rear support.

thanks for that link radrino. I did a search but looked for axles coming out, and ignored the broken axle treads.
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post #6 of 15 (permalink) Old 02-27-2011, 11:10 AM
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There is a updated axle snap ring also, had no problem after I changed to them
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post #7 of 15 (permalink) Old 02-27-2011, 11:28 AM Thread Starter
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dudecan, i think i have those snap rings (circlip?). It has square cut edges instead of rounded edges
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post #8 of 15 (permalink) Old 02-28-2011, 12:51 PM
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If all measurements are right and they still keep popping out just bolt them together.. Thats what I did and have never looked back.. I run WITHOUT inner c-clips or inner cir-clips and they never popped out again.

Here is my post with pics.
https://www.rhinoforums.net/suspensio...-together.html

John
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post #9 of 15 (permalink) Old 03-14-2011, 12:25 AM Thread Starter
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I'm at my wits end on this!! I got rid of the 27" tires and 14" rims, put on 12" rims with 27" Bighorns. I put in a swaybar, and replaced both lower A-arms (bushings were sloppy). REPLACED both sides with the all-new-problem-solved Super ATV axles, and POOF, 5 minutes later the left side pops out again.

boy, are the angles ever tight on these axles. there is only millimeters separating axle from rubbing the shocks.

so I see the inner cups bolt thru set up. Undoubtedly that would work. But it looks like a ton of work. And I'm not great at taking apart CVs, but I've seen it done. Seems like a pain if you ever have to take out an axle, for either side. What's it like getting the axle shaft off/on those inners? what about taking it apart later? my experience with getting an axle apart involved some heavy pounding, so i can't see pulling the axle off the inner easily. any damage to the diff from taking these apart?

Is it possible the diff is the issue? Is there some other answer?
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post #10 of 15 (permalink) Old 03-14-2011, 06:05 AM
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Take a look at your rear diff mounts. Is there any signs that the rear diff mounts have ever been welded on? Next. Remove the shock on the side that the problem is occuring on and cycle the suspension to see if the axle is the right length. You should be able to tell if the axle is pulling on the inner CV at all. If it is pulling on it at all your axle is too short.
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post #11 of 15 (permalink) Old 03-14-2011, 06:24 AM
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or jack up the rear and let the axels fall out all the way and see if there to short ,i had to have sommers bro's make my driver side a 1/2 inch longer and it solved all my problem's i ended up ,gussiting the diff and strapping the rear aswell as a precaution ,now i got steering weakness so thats next...lol alway's something....

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post #12 of 15 (permalink) Old 04-18-2019, 02:08 PM
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What is the issue with rear diff mounts having extra welding? My 2006 660 is pretty much stock and the rear left pops out all the time. I thought it was just the clip not seating fully, but it definitely seated the last time and it is still popping out. No lift kit or LT. WTF is going on?
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post #13 of 15 (permalink) Old 04-19-2019, 02:57 PM
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Quote:
Originally Posted by preston View Post
What is the issue with rear diff mounts having extra welding? My 2006 660 is pretty much stock and the rear left pops out all the time. I thought it was just the clip not seating fully, but it definitely seated the last time and it is still popping out. No lift kit or LT. WTF is going on?
I pulled mine apart one time to replace the seal, believe it or not I put the knuckle in upside down and the axle popped on the first ride.

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post #14 of 15 (permalink) Old 04-25-2019, 06:08 AM
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.....

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post #15 of 15 (permalink) Old 04-25-2019, 09:27 AM
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Quote:
Originally Posted by radrino View Post
or jack up the rear and let the axels fall out all the way and see if there to short ,i had to have sommers bro's make my driver side a 1/2 inch longer and it solved all my problem's i ended up ,gussiting the diff and strapping the rear aswell as a precaution ,now i got steering weakness so thats next...lol alway's something....

Off topic but I've also had multiple issues with the rear diff mounts in the short amount of time I've had it. The 4x tiny tabs are not nearly strong enough. I reenforced mine a little but really should have put gussets on too.


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