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Old 11-16-2009, 06:02 PM
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silverram323 silverram323 is offline
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Default My write up on replacing the DD bearing

Here you go guys. I took pics and installed the new bearing from bdx.
I would definitely recommend that you take the DD gear case out of the sled. It is way easier then one thinks (10 minutes tops, even for the beginner)

1. Loosen up the track.

2. Take out the 16 MM bolt inside of the brake rotor. You will need some extensions.

3. Take off the belt cover on the foot well. (4 t20 bolts)

4. Take off the 8 13mm/1/2" nuts that hold on the DD unit. Don't touch the rubber mount to the left of the DD unit.

5. Grab the shaft for the secondary clutch and give it a wiggle, and it will separate from the track drivers.

6. Grab a roll of duct tape and set your DD unit on it as a holder.

Now its much easier to work on.


Here is my other write up on the DD case bolts.

I started by taking the belt off the secondary then pull the secondary off. I then took off the bracket bolted to the foot board. That was in the way from the DD gear cover to pull straight off.



Then i took all the T-30 torx bolts out. I think 13 total.


then i gently pulled the cover off as to not tear the gasket.




then brought the cover to the work bench.


Then i pulled the lower gear off.


I used a pitman arm puller ($15 at napa) to get the 6203 bearing off. I had to stack a 5/32 socket on the gear for clearance.

Last edited by silverram323; 12-02-2009 at 06:09 AM.
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Old 11-16-2009, 06:02 PM
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silverram323 silverram323 is offline
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Default My write up on replacing the DD bearing

I put the pitman arm puller in the vise and pulled the 6203 bearing off.




So i took the old bearing (6203) and the shims off and pressed on the new bearing (5203) till it seated all the way down.




My cover wouldn't snug up tight so i had to loosen the 16 MM bolt inside the shaft of the brake rotor.


Tipped it on its side to fill it up.


Put the secondary clutch back on, slide the belt on and your done.
If i didn't have to take pictures i could have done it in 20 minutes.
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Last edited by silverram323; 12-01-2009 at 08:39 PM.
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Old 11-16-2009, 06:15 PM
fasta76 fasta76 is offline
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Great post!! I went through the same thing with mine!!
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Old 11-16-2009, 06:47 PM
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This is excellent, thanks for taking the time.
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Old 11-16-2009, 08:29 PM
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Quote:
Originally Posted by silverram323 View Post

Stock junk torx bolt.
That is a tri-lobe screw and they really aren't meant to do what was done there - I bet they cast in the holes at the minor diameter of the thread then add a bit of draft angle into the casting and then let the screw cut its own thread instead of going with proper secondary ops to cut good threads into the housing.

You can get away with it but alloys, holes, and fasteners have to be just right and really shouldn't be something that is a service area.
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Old 11-17-2009, 07:43 PM
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good job showing us how its done
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Old 11-21-2009, 01:48 PM
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TTT.
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Old 11-21-2009, 02:08 PM
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Good thread.
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Old 11-21-2009, 02:16 PM
M.M. 700 M.M. 700 is offline
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If you do not have a press. A workbench vise works great.

Take a block of wood, and put that between the teeth of the vise and the gear/bearing. Line up the bearing on the gear shaft, and slowly tighten till the bearing bottoms out.
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Old 11-22-2009, 09:55 PM
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Nice, I'm doing mine next week. thanks, you did a nice job putting that together
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