Quantcast
Jump to content

  • Do you own an ATV? Join our Forum!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

killer420

Rancher 420 2wd to 4wd conversion

Recommended Posts

I know this has been talked about, so i did some research.

After my research, i started buying parts.

Here are the parts you need:

51380-HP7-A00, left front upper control arm

51370-HP7-A00, right front upper control arm

51350-HP5-600, right front lower control arm

51360-HP5-600, left front lower control arm

44615-HP5-600, front drive hubs (need 2)

53521-HP5-600, tie rods (need 2, this is just the adjuster rod, not the tie-rod ends)

51200-HP5-600, right steering knuckle

51250-HP5-600, left steering knuckle

53235-HP5-600, steering arm (connects the tie rod ends to the steering shaft)

23611-HP5-600, "final shaft", goes inside the engine, provides power to front and rear driveshafts)

40400-HP5-600, front driveshaft

44250-HP7-A31, right front axle

44350-HP7-A31, left front axle

11300-HP5-000, front crankcase cover

50350-HP5-600, front differential support bracket

41400-HP5-A50, front differential unit

You also need the 4wd shift lever and the cable that connects it to the differential. there is not a part number for the whole assembly, just look on ebay. thats where i got mine.

Now on to the good part, the turning of wrenches:

Here is the engine before removal:

IMG_20151128_143827.jpg

IMG_20151128_143843.jpg

after removal:

IMG_20151128_160214.jpg

front differential in position:

IMG_20151129_135507.jpg

^^^notice the "TRX420TM" decal, indicating 2wd

Here is a pic of the "final shaft", comparing the 2wd (in my hand) to the 4wd (in the engine).

IMG_20151129_135842.jpg

^This is the most difficult part of this conversion, removing and opening the engine to swap out this shaft. However, there is a lovely video on youtube showing how to rebuild this engine and they clearly show the steps to remove/replace the rear cover and final shaft. Dont forget to remove the front cover before installing the new shaft, it will not fit thru the 2wd front cover.

link to video>:

once the new shaft is installed:

IMG_20151129_140055.jpg

you will need to install the front and rear covers using sealant, make sure all shims/washers and o-rings are in place in the correct locations referencing the video above.

here is the right front corner mostly assembled:

IMG_20151130_124400.jpg

and fully assembled with hub, rotor, and brake caliper:

IMG_20151130_172332.jpg

I do have more pictures to upload, when i have more time i will update this further

  • Like 2

Share this post


Link to post
Share on other sites


if anyone cares (which i doubt since its been 9 months since i posted this), i only spent $750 on the conversion overall. everything worked flawlessly first try. i used this honda to plow 30inches of snow from a steep 800ft driveway. never missed a beat.

 

it was WAY cheaper than selling my 2wd rancher at a big loss and buying a 4wd version. if you can turn a wrench this is not too difficult for you to do at home

Edited by killer420
  • Like 1

Share this post


Link to post
Share on other sites

Dude you rock. I want to do this to my 2016 420 rancher es. Think it's just as feasible? 

As much as you can tell me will help mate

Share this post


Link to post
Share on other sites

it will probably cost a little more than it did for mine, i was able to source some a couple used parts for much less than new. For instance, a new front diff for mine was $675, i got a used one for $80. it may be more difficult to source used parts for such a new machine.

from some quick poking around on rockymountainatv.com using their Honda OEM catalog, it appears you will need to change your front knuckles, get front axles and differential, change front cover on engine, change final shaft in engine, change front tie-rods, add 4wd shifter and cable

 

 

if i have time tonight after work i will try to get you a list of part numbers you would need

  • Like 1

Share this post


Link to post
Share on other sites


Thanks for the build sheet. About to do this to a 2010 Honda TRX420 TMA . The pictures would be a big help if I could see them

Edited by Muddyhonda
Added

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


  • Similar Topics

    • By Karen McDowell
      Went to change oil and get my sons  2000 Suzuki King Quad 300 ready for spring and found the left front wheel wont move at all but the right does. Doesn't matter if it's 2 or 4 wheel drive same issue. Nothing looks bent, tie rod ends and ball joints in place jacked it up and shook wheel and bearing seems tight. Any ideas before I tear the dang thing apart?  Of course my son has no idea what happened.  
    • By Hellraiser69
      Just got a new to me, 99 Kodiak w/ plow and an extra set of tires for dirt cheap. I'm curious where you guys purchase your parts for your older ATV's? Google is great to find parts, but I'm hoping you guys have some stores, online, that you prefer on a recommendation basis. I've already purchased my tune-up items, but the brakes need some work and I'll likely end up having to replace the steering stem bearing, front CV axles and a few other things down the road.
    • By Randel1
      I am trying to put a 1994 Suzuki 250 quadrunner back into service. I have it up and running like new but need to replace the plastics as they are brittle and crumbling due to age and sun exposure. I would like to purchase new parts either OEM or aftermarket but have had little luck in finding them. I would even consider used or salvaged parts in serviceable condition. Any help in locating these parts would be greatly appreciated. Thanks in advance.
    • By MarkinAR
      So just as a general FYI, it might be good to check replacement parts before installing.  If possible, check clearances with a micrometer before going through the trouble of assembly.  I say this as I bought a new driveshaft yoke for a Kodiak because the ujoint dropped a cap and got the yoke in a bind...blowing the yoke and middle drive gear to shreds.  So I replaced the middle drive gear and bought a new yoke and ujoint kit from Caltric.  Caltric is usually pretty solid replacement parts.  The new yoke however was a good 4mm too narrow for inside lock ujoint caps.  Disappointing since it came as a kit from Caltric.
      Ended up taking an angle grinder to the new yoke and thinning material off to get it to the needed 41.25mm opening size.  Sucks having to disassemble everything again and start over but my fault for trusting replacement parts.  Nearly 40 years of turning wrenches and I made a rookie mistake.
  • Similar Tagged Content

    • By ntl8484
      I collected two months. Wheel diameter of 1 meter, width of 0.5 meters. All wheel drive.
       
       
    • By anthonyd256
      I have a 99 Yamaha bear tracker and I have converted the front brakes from drum to disc fairly easy but I cant figure out how to convert the rear with out hacking apart the rear arm. tried to use parts from a wolverine since the rear arms look similar but the caliper mount didn't line up on the bear tracker axle. Can anyone give me any clues or has anyone successfully converted the bear tracker rear brakes. I would even purchase a conversion kit if there is one. Any help on this would be greatly appreciated.
    • By cprservices
      Does anyone on here have a 2013 honda rancher? I have had several Honda ranchers in the past but I bought this 2013 rancher and it hits the rev limiter at half throttle. It is very annoying and I was wondering if anyone else's Rancher does this. If this is something from the factory or if I have a problem or not just trying to figure it out. Any help would be appreciated
    • By freightwrench
      Anyone know how many links in the drive chain to the front wheel drives on the 1995 sport 400 2 stroke if it makes a difference. thanks in advance freight:GEEK:
  • Recently Browsing   0 members

    No registered users viewing this page.


×
×
  • Create New...