How To Remove a KYB Coverplate in the Field

Here at Final Drive Parts, we get quite a few calls from customers that have been struggling to get the cover plate removed from their Kayaba (KYB) final drive. This is a notoriously difficult cover plate to remove, so we’re going to talk about how to get that stubborn cover off in the field using everyday tools like those shown in the image below.

Taking Out the Drain Holes

This cover plate can get rusted badly that you may need to let it soak in some penetrating oil before you try to remove it. Then take out both of the drain holes on top. You may need to dig out some of the dirt and debris from around them to get them loosened.

Finding the Wire

On the side of the final drive you’ll find a set screw that needs to be removed. Remove this set screw. Inside the opening for the set screw there is a metal wire that goes around the cover plate and acts as an internal snap ring for the cover plate. You should be able to see it using a flashlight.

If you can’t see the wire, then you are going to need to go to a bit more effort. Find some bolts, fittings, or something similar to screw into the plug holes on the top of the final drive. You may want to modify one of the bolts or fittings to allow a slide hammer to attach to later on to take the cover plate off. Make sure they are screwed in tightly to the plug holes, otherwise they will break off.

Now put a cheater bar or pipe between the bolts/fittings and slowly turn the cover plate until you can spot the wire. The picture below shows the cheater bar and modified fittings in place and ready to be used.

Removing the Wire

You will need to pick the wire out with a normal, everyday pick or a flat-head screwdriver – anything you can find that will work. You need enough of the wire protruding from the final drive so that you can grasp it with a pair of pliers. You may need to pick it out, turn the cover plate slightly, then pick it out a bit more, until you have enough wire to grasp with a pair of pliers.

Grasp the wire with the pliers, and then turn the cover plate at the same time so you are, in essence, spinning the wire out. The wire goes all the way around the cover plate. You can see Travis spinning the wire out in the picture below.

Note that occasionally there are going to be four set pins along the outer hub. These are holding the cover plate in place and all need to be punched in order to rotate the cover plate to extract the wire.

Popping the Cover Off

Once you get the wire out, take your slide hammer and screw it all the way into the modified fitting. Get it as tight and snug as you can, then use the slide hammer to loosen the cover and pop it free of the final drive housing.

Conclusion: Kayaba KYB Cover Plate Guidelines

The Kayaba KYB cover plate is undoubtedly a challenge to remove in the field, but it can be done as these guidelines show.