My ES is too dang reliable and I find myself with extra time on my hands, time that others seem to use working on their machines. For us ES owners, what do we do with that extra time?
Please and Thank You.
WM
ES Owner
You'll undo a bolt on the bottom of the front diff (14MM), a bolt and spacer on top of the diff (I think 14mm on nut/bolt) and the mount on the front of the diff. I remove the metal bracket on the front, or at least unbolt it, and loosen the bolt so you can swivel it out of the way.
That's it. Pull the front diff forward. The prop shaft will then just slide out.
Check and see if you need the prop shaft or the coupler, or both. Also check the splines on the shaft coming out of the engine. They should be square cut, not pointed. If they're pointed (shark toothed) they're worn out.
Used Shaft
https://www.ebay.com/itm/296213716938?epid=1911839859&itmmeta=01HVRVTQP5BSREC4RFXBMWHXNG&hash=item44f7b69fca%3Ag%3AA7MAAOSw9cRlxUff&itmprp=enc%3AAQAJAAAA8HJls4L8zrcD5BV69nyIFrpoNL4tguslMY9%2FXJBfvkAgiUjPZtgcCS%2ForBApuqsc%2FBFlBlCf0pzHMTAwMcoEBj6n3PkpDrg%2Fca9DB%2FOJ--3eGB%2Bz%2FdoDysjhrTzXWjxX2GfX%2BkoNj5r9WQQewOnV29CxZL%2FG7Z2vL%2FcYHWyb69QzRsULM4aqgwzJwzPzmkYmssvVhrXztzrjyXZv%2B3mXpBLWHUEw7yTLEUQL1CKBVh7ipWluy5w95VCYdFWCFxVV0I2HRA2X%2F2ZAeetS29FF48w0wyPQd0KAvW%2FqwHN0wQXOXukFt7B9UspDeyg%2BwZWpSQ%3D%3D|tkp%3ABk9SR5L76pveYw&LH_ItemCondition=4
Used Coupler
https://www.powersportsnation.com/honda-rubicon-500-fa-02-front-drive-shaft-engine-coupler-40402-hn2-000-44196.html
If you want new, part number for complete shaft and coupler is 40400-HN0-670 and it's about $200.
https://www.motosport.com/oem-parts/part-number/40400-HN0-670?mmy=honda%3Btrx450 foreman 4x4 es%3B2004&group=front-final-gear&qty=1
Those are the cheapest used parts I could find, and the cheapest new shaft I could find. Note that you need 02-04 only. The earlier 450's were full time 4wd so the shaft is different.