2007 XRT 1550 Honda GX620 Front popping when 4x4 is needed

[thegadget]

I really hate having to ask for help, but before I start throwing money at this thing, I would really love your opinion on what this could be. This is the gas powered version with the Honda GX620 (20hp). When you accelerate from a stop, the steering wheel pulls strongly to the right. If 4wd is needed, the back wheels spin, but the front "Pops" loudly and will not spin either wheel. I plan on jacking it up and checking the front differential. I am trying to decide if I should replace the Axels or the Front Diff. It acts like it is trying to "grab" but just barely moves back and forth. I can buy a set of front axles for about $400 new, a used diff is $800. Thank you for your insight, I can see the diff moving when the POP is heard. Is it hard to rebuild the diff? The rebuild kit is around $900, and I would just replace the whole unit. :)

[dundeebarnbuggy]

Before buying $#it, take the friggin' thing apart and find out WHAT exactly is worn out or broken. Mechanics 101.

[thegadget]

Yes, you are right. I will have fun pulling it apart. I will try to post pics.

[CP241]

Yes take it apart and see what’s broken before ordering anything.

My guess, (which is a shot in the dark) is a worn pinion bearing in the front diff. This would show by the drive shaft turning and little to no action to turn the front wheels if the pinion is not able to engage the ring gear and transfer the power to the wheels.

Again, just a guess but that’s my bet. Let’s start a pool I’ll throw in a dollar for beer money

If it is the pinion bearing exploded, there’s a better than not chance the pinion and ring gear have abnormal wear on them. So tear apart and inspect carefully.

Let us know what you find!

[Cartmaster]

If the setup is similar to the Kawasaki mules, then CP241 is spot on. The input shaft bearing collapses and the gears no longer mesh correctly and very quickly destroy themselves. If so, it is as you say, cheaper to replace than repair.

I currently have a similar issue with a John Deere tractor and it works out a grand cheaper to replace than try to rebuild.