Im working on a 1994 Honda Passport 4WD Im trying to replace the front halfshafts but i cant get them out of front differential is there a trick

It connects to a hub with
6 bolts which is connected to the front differential.

Bad neutral switch on the trasmission

FSM
Remove the halfshaft from the vehicle and secure in a vice equipped with jaw covers.
During joint service, reference marks should be placed on the joint housing, halfshaft and joint spider to ensure that all components are installed in the same position from which they were removed. If this precaution is not observed, uneven or premature component wear may result.

1. Remove the large differential boot clamp by drawing the clamp hooks together using tool J-35566 or equivalent.
2. Remove the small differential-side boot clamp. Slide the differential-side boot toward the center of the halfshaft. Place a reference mark on the differential-side joint housing and halfshaft.
3. Remove the differential joint housing from the Tripod joint spider. Place an index mark on the Tripod joint spider and halfshaft.
4. Remove the snap-ring and Tripod joint spider from the halfshaft.
5. Remove the differential-side boot from the halfshaft.
6. Remove the boot clamp from the wheel-side boot.
7. Remove the small clamp from the wheel-side boot.
8. Remove the wheel-side boot from the halfshaft. Place a reference mark on the wheel-side joint and the halfshaft.
9. Remove the wheel-side joint from the halfshaft by expanding the snap-ring.

Do not disassemble the wheel-side joint. If any abnormality is found in the joint, replace it. Do not disassemble the Tripod joint spider. If any abnormality is found in the spider, replace it as an assembly. Do not wash CV-joint boots or spider in solvent. Clean the spider assembly and boots with a clean, dry, solvent-free rag.


best it to buy the FSm book and see photos.
or join alldata.com and read this, same reason.

find a live hands on mech. for all noise......
finding the sources of noise takes, hands on,
and can be dangerous to find, and to continue driving,.
and this car is not AWD, its really a part time , 4wd, made by ISUZU.
this car is honda. , badged Isuzu.
do not drive in 4wd on dry pavement , only on ice or dirt.
or you will wind up the driveline and damage it. that is the cause of the terrible noise, im sure.
see why here
http://www.fixkick.com/part-time-test.html

now the 2wd.
that is a whole other matter if you didnt already damage parts
in 4wd.
data:
The Honda Passport was a badge engineered version of the Isuzu Rodeo released in 1993


the Rodeo has no center differential, so can not drive
on dry pavement (ice free) safely nor damage free.

Have not done this on your truck but book says just the upper ball joint needs separated. See procedure below from autozone.com. Please let me know if you have questions.

1. Remove or disconnect the following:
   
   Front wheels (left side should be sufficient in your case) Front hub cotter pin, retainer and nut (axle nut)
   
2. Using a floor hydraulic jack, support the lower suspension arm.
   
   Upper ball joint cotter pin and castle nut Knuckle from the front suspension upper arm
   
3. Lower the lower suspension arm and steering knuckle slightly to facilitate easier halfshaft removal.
4. Remove the 2 disc caliper mounting bolts, then lift the front disc caliper off of the front disc brake caliper anchor plate and position aside. Do not allow the caliper to hang by the brake hose; suspend it from the vehicle's frame with strong cord or wire.
5. Remove the 6 front halfshaft-to-differential bolts.
   WARNING Use care to avoid damaging the hub seal when removing the front halfshaft.
   

   

Fig. Halfshaft-to-differential mounting bolts (3 of the 6 bolts shown)-2001-03 F-150 and 2004 F-150 Heritage Edition

7. Remove the inboard end of the halfshaft from the differential case or extension axle case. Separate the front halfshaft and joints from the hub, then remove the halfshaft and joints from the vehicle.

To install:

1. Slide the halfshaft outboard end into the hub, making sure that the splines engage.
2. Situate the inboard end of the halfshaft against the front differential flange and install the 6 halfshaft-to-differential bolts. Tighten the halfshaft bolts to 60 ft. lbs. (82 Nm).
3. Install the front disc brake caliper onto the rotor and anchor plate, then install and tighten the 2 caliper mounting bolts to 21-26 ft. lbs. (28-36 Nm).
4. Lift the lower suspension arm and steering knuckle up until the upper ball joint stud is inserted into the steering knuckle. Install the upper ball joint castle nut and tighten to 57-76 ft. lbs. (77-104 Nm). Install a new cotter pin.
5. Install the hub nut onto the halfshaft and tighten the hub nut to 221 ft. lbs. (300 Nm).
6. Install the hub nut retainer and a new cotter pin.
7. Install the front wheels and tighten the lug nuts in a star-shaped sequence to 83-112 ft. lbs. (113-153 Nm).
8. Lower the vehicle to the ground.

Hello rgpkrbkr and thank you for asking your question, on Fixya.

Here is a simple process that will walk you through a few steps that will pinpoint the overheating problem on your 1994 Honda Passport, without even using any tools. It has helped millions of people, and I am certain that it will help you, because I wrote it for people in your exact situation.
How to diagnose your overheating 1994 Honda Passport


Get more great (money saving) tips and tricks about your vehicle from: twitter.com/acoates23234

Thanks for the vote, and good luck!

Rear. In Europe was on sales until 2003 (last line made) by OPEL as frontera. Equipped mostly with 2.2 Turbo diesel engines, rear wheeler, ability to engage 4WD, under motion up to 60MPH, having automatic front diff locks, and despite the bad critics about crash tests and behaviour, well sold. Still on the roads.

REMOVE FRONT WHEEL/.REMOVE THE REINFORCEMENT PLATE / REMOVE FRONT SPLASH GUARD / REMOVE ABS PULSE GENERATOR / REMOVE BRAKE CALIPER FROM DISC AND TIE OUT OF THE WAY WITH THE HOSE STILL CONNECTED / REMOVE STEERING GEAR TIE ROD FROM SWIVEL BEARING / REMOVE THE TENSION STRUT WITH GUIDE JOINT FROM SWIVEL BEARING / REMOVE THE CONTROL ARM FROM SWIVEL BEARING / REMOVE THE COLLAR NUT ON HALFSHAFT PRESS HALFSHAFT OUT OF DRIVE FLANGE / REMOVE THE HALFSHAFT.BESURE TO REPLACE THE SNAP RING ON THE HALFSHAFT.WHEN INSTALLING HALFSHAFT BESURE TO PUSH IN OUTPUT SHAFT OVER THE RESISTANCE OF THE THE RETAINING RING UNTIL IT SNAPS IN PLACE.WHEN JOB FINISHED CHECK THE FRONT AXLE DIFFERENTIAL FLUID LEVEL.

Bad u-joints at front driveline and/or u-joints at axle connection from behind rotors- going into front differential. Need new u-joints at either the driveline front and back (going into differential or to Transfer case) or the Left and Right side axles going into the differential. Put Locking (or "Lock-outs) hubs on front axles... WARN brand are best... about $75 a pair and you can do it yourself, easily.

1997 Honda Passport 4wd
Make sure you have the correct factory Honda starter in your car , if its an aftermarket starter they may have replaced with cheapo starter,sometime the teeth that engauge starter to your flexplate will not mesh properly,because there different,causing the flex plate to fail. I had the same problem. I went thru 2 before I found this out..Hope this helps.
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