Need help removing main gear from rear axle

[shorty]

Is there a secret to removing the set screw that seems to hold the main gear onto the rear axle, or should i just accept the fact I will lose all my knuckles before this adventure is finished?

I'm mucking out a 2003 Max IV i just bought. The Max was hardly used but the previous owner obviously wasn't big on cleaning and maintaining it either. I lifted out the engine and tranny, and wanted to grease the inside rear bearings. With a 90' coupler I was able to get grease into one zert. But no luck with the other side bearing. I thought if I moved the gear, i could try a straight coupler, clean the zert and or change it or the flange. That's when i met the set screw from hell.

The axle is splined; the gear held to it with a set screw like you would find on a bearing collar (very different from the bolt holding gear to axle on my '93 Max.

QUESTION: can i move the gear to get at the zert? Is the zert pressed into the flange or is it screwed? Does anyone know where to get zert extensions? There is NO WAY to make these bearings part of the regular weekly maintenance without some serious modifications. A midget gymnast couldn't service those bearings, never mind me, the Friendly Giant.

[Mike]

You may have to try a little heat or you can sometimes lightly tap the sprocket tube or set screw with a punch / hammer to vibrate it a little. The zert on my inner flange is screwed in not pressed in so you should be able to throw a wrench / socket on it and back it out if you have to. Good luck!

[Castro]

try impact that you hit with hammer

Try an impact. One that you hit with hammer and it loosens it just a little. That's what I had to do, glad I did before I rounded it. Bond auto had these on sale for 12 bucks last week

[LarryW]

Castro, I know what your talking about. They do work great. I believe its called an impact driver. To double check I googled and was correct and found this info that helps define the difference between a impact drive and impact wrench. Basically its the downward force. I found it interesting and thought I would share.

"An impact driver is a tool that delivers a strong, sudden rotational and downward force. In conjunction with toughened screwdriver bits and socket sets, they are often used by mechanics to loosen larger screws (bolts) and nuts that are corrosively "frozen" or over-torqued. The direction can also be reversed for situations where screws have to be tightened with torque greater than what a screwdriver can reasonably provide........................

.........These are not to be confused with the impact wrench, which is a motorized tool (usually powered by compressed air), with a similar name and function. These also use a hammering action to apply torque to fasteners. The difference is that impact wrenches do not provide the positive engagement that impact drivers offer as mentioned above. This is desirable though on hex head fasteners and others where the downward seating action is unnecessary and potentially damaging. To add to the confusion, they look identical to motorized impact drivers."

[shorty]

And the Winner is.....Mike of Heat and Tap fame! Well, at least I think you will be the winner. We'll have to wait until the weekend before I can try it. Hopefully I won't burn down the garage.
I called Recreatives to find out the bearing sizes. Man, they have good service. They told me that the set screws have Loc-Tite on them and that heat and tap is necessary.So we'll see.

RI also told me that the outside bearing were 3 lip or tripled sealed. I called Kinecor and the nice lady called me a bunch of names that basically weren't too complimentary. And she said she never heard of such a thing. Does anyone know of a place to order such bearings from (in Canada hopefully)? I'll post this question on a separate thread but thought I would try it here first.

Thanks everyone.