Diamond Drive removal and inspection tortural

dezmitchell · Nov 5, 2010

ZRrrr said:
Where did you hear that P?N 1602-745 can be problematic.

A tip for the rubber bump stop is to spray it lightly with WD or equivalent before replaicing. Slides in a little easier.

Good write up.

I was told this by the cat dealer here .....Maybe he was just doin the ol sales pitch on me but for the 13.74 it dinged my bank account its worth it in my mind ......Also seems to be the only plastic part in there so made sence to me why it could be problematic....

As for the WD tip thanks never thought of that.... this is what this thread is all about.:d:d

dezmitchell · Nov 5, 2010

Pistonbroke said:
Great post.

Just curious....did you mean to spell "tutorial" the way you did? :d

lol no

a already got some rep saying that i would make a better shop teacher then an english one.:d:d:d

woodym7 · Nov 5, 2010

no i have not yet it is under my desk and im gonna take it down to the dealer here in a few minutes...to see what the deal is each piece turns silently on their own however when you add them togeather you get a definate noise soudns like a 64 tooth snap on rachet if ya now what i mean......anyways i will let you know when im down everything else has gone according to plan though.....tks again:d:d:d

Pistonbroke · Nov 5, 2010

dezmitchell said:
lol no a already got some rep saying that i would make a better shop teacher then an english one.:d:d:d

repped that! :d :beer:

ZRrrr · Nov 5, 2010

dezmitchell said:
I was told this by the cat dealer here .....Maybe he was just doin the ol sales pitch on me but for the 13.74 it dinged my bank account its worth it in my mind ......Also seems to be the only plastic part in there so made sence to me why it could be problematic....

As for the WD tip thanks never thought of that.... this is what this thread is all about.:d:d

I'll be sure to take it under advisement and have a closer look next time in the case. :beer:

woodym7 · Nov 5, 2010

so just did a track swap and split my dd while i was doing it found the double wide bearing shot after 3000 miles, so long story short had dealer change the bearing for me and once installed it made a sound like a really good rachet would sound...gears clicking away.........through inspection and multiple rebuilds on my end, I found that if the retainer clip is installed wrong it will make this noise that i have mentioned, so if you hear sounds after the rebuild check this first do not install and try it will grenade.....

might sound stupid to some of ya, but it scared me and such a simple thing, the worst part is i kept installing the clip the same way since thats the way the dealer had put it in......

scrfce · Nov 5, 2010

thx,,,,ill be coming back to this thread in the future when i do mine.....in the first post you said a case of beer optional but said nothing of the rye and coke that it looks like you were drinkin, what gives?

dezmitchell · Nov 5, 2010

scrfce said:
thx,,,,ill be coming back to this thread in the future when i do mine.....in the first post you said a case of beer optional but said nothing of the rye and coke that it looks like you were drinkin, what gives?

you say tomato i say tomato:d:d

macronut · Nov 5, 2010

dezmitchell said:
Well boys and girls that about raps it up now all you have to do is fill DD with oil and bolt everything back up. Now i am going to wait until tomorrow to fill my DD its a good idea to let the silicone sit for 24 hours and seal up really nice b4 you fill it up with oil.

All you have to do after the DD has oil in it is bolt the DD back to the bulk head. Now for this i tip my sled on the side that way i get a better view about whats goin on and lineing everything back up.

NOTE--- dont forget to reinstall that small wire back in the DD this is for your speedo and if you forget this you will be kickin yourself.---

Once DD is bolted up (use blue thread lock on the 6 bolts) place that pesky rubber piece back in place----this covers that hidden bolt again---- and Torx the 2 fasteners back up.

Go around to your brake side and reinstall that long bolt with a touch of blue lock tite as well

Then mount your 2ndary back on the DD (also with some blue thread lock).

And WALA!!! your sled is back together and ready for another season or trouble free riding.

Awesome post, great for us Newbies to save the$$$$$ and use it for oil and fuel etc.... Thanks again

calgarysledguy · Nov 5, 2010

One thing i found in my 06 m7 diamond drive when i pulled it apart was that the Transfer gear where the other gear was welded on,the weld was cracked. Not sure if its a common thing.... But something to look at when you got it apart. It was pretty hard to see it.You have to look close at it. It may have lasted 2000 miles or maybe 10 who knows...

Good write up. :beer:

Rucky · Nov 6, 2010

I'm not sure if it would hurt, but on the newer diamond drives, there is a proper gasket rather than RTV. Also... I'm not sure about loctite on the secondary bolt on the newer ones. That bolt also doesn't need to be crazy tight. I got a full service manual for my sled online for $80.00. Probably the best investment for it. It has some very valuable information in there; HOWEVER, the torque they specify for those ridiculous little torx bolts was too high and I stripped on of them. Man was I ever pissed.

Polarblu · Nov 6, 2010

calgarysledguy said:
One thing i found in my 06 m7 diamond drive when i pulled it apart was that the Transfer gear where the other gear was welded on,the weld was cracked. Not sure if its a common thing.... But something to look at when you got it apart. It was pretty hard to see it.You have to look close at it. It may have lasted 2000 miles or maybe 10 who knows...

Good write up.

other welders can chime in but this looks to me like improper cooling and was probably there from the factory.

Bulldog Racing · Nov 6, 2010

This is an awesome post. Now if some one could show us the trick to install a set of V-Force reeds so that we don't have to remove / install the throttle body's and air boot about 3 times. Someone has had to figured out an easy way to do this. :rant:

CRFSummit · Nov 10, 2010

Hey, noticed in one of the pictures on your second post, your drink is empty.....how many did it take to do the full job!!
Don't know much about the dd, but what do you need to do to just change oil?
Thanks

Pistonbroke · Nov 10, 2010

CRFSummit said:
Hey, noticed in one of the pictures on your second post, your drink is empty.....how many did it take to do the full job!!
Don't know much about the dd, but what do you need to do to just change oil?
Thanks

What we've been doing is:

-remove clutch
-remove DD outer housing
-remove planetary and gears
-clean all parts and inside of housing with brakeclean
-refill and reassemble.

The main DD case and track drive shaft stays in the sled.

dezmitchell · Nov 10, 2010

Pistonbroke said:
What we've been doing is:

-remove clutch
-remove DD outer housing
-remove planetary and gears
-clean all parts and inside of housing with brakeclean
-refill and reassemble.

The main DD case and track drive shaft stays in the sled.

PHHHH thats way to easy....:d:d

Shredder · Nov 10, 2010

Pistonbroke said:

What we've been doing is:

-remove clutch
-remove DD outer housing
-remove planetary and gears
-clean all parts and inside of housing with brakeclean
-refill and reassemble.

The main DD case and track drive shaft stays in the sled.

Click to expand...

That sounds like the way to go for sure. Just roll the sled on it's side; crack a fresh beer and you're half done already.:d:d

cueball115a · Nov 10, 2010

Well I want to thank you good post , I'm sure this will help me soon.

:nono:

kchop · Nov 14, 2010

Thanks for the post. Im new to the sight just followed your tutorial on my 05 M7 made it simple for me. :beer:

justn · Dec 7, 2010

I'm having trouble getting my clutch off. I have an '06 m7 with the plastic ring on the end of the clutch. I took that off, and the bolt out, but the clutch still won't come off. I even did a little prying with a pry bar and no luck. Am I missing something?

I got the clutch off! Finally! It took some soaking it with WD-40 and some persuasion with a rubber mallet to do the trick. After that came off I got the DD out and apart no problem. Everything cleaned up nicely, sounded smooth, and there was no play or metal filings to be found. This makes me very happy considering this is the first time its ever been open and even had its oil changed.

Diamond Drive removal and inspection tortural

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