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killer420

Rancher 420 2wd to 4wd conversion

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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

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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
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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

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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

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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
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