Front dif leaking out of drive shaft hole - Polaris RZR Forum - RZR Forums.net

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post #1 of 9 Old August 20th, 2010, 11:30 AM Thread Starter
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Front dif leaking out of drive shaft hole

Went to go riding this weekend....I realized a little fluid leaking out of my front diff on my skid plate. It is not leaking from the cvs it is leaking from where the drive shaft goes in. Have not checked how much has leaked out yet but I don't think it's too much. I am wondering what needs to be done to fix it and avoid it from happening again.
Also,how many labor hrs am I looking at/how difficult of task?

Any input is appreciated.....thanks a lot.

-Zac
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post #2 of 9 Old August 20th, 2010, 11:59 AM
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Re: Front dif leaking out of drive shaft hole

Prob just pull the drive shaft and replace the drive shaft seal on the front dif. Pretty easy to do
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post #3 of 9 Old August 20th, 2010, 12:40 PM
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Re: Front dif leaking out of drive shaft hole

here is the parts drawing for a 2008:



# Add Part# Description Quantity
1 2203726 Asm., Output Cover 1 Usage
2 ------- Seal, Oil 3 Usage
2 ------- Seal, Oil 3 Usage
2 ------- Seal, Oil 3 Usage
3 ------- Cover, Output 1 Usage
4 ------- O-Ring 1 Usage
5 ------- Coil, 4WD 1 Usage
6 ------- Grommet 1 Usage
7 ------- Pin, Dowel 1 Usage
8 2203731 Screw, Set 1 Usage
9 2203732 Button, Thrust 1 Usage
10 2203727 Asm., Output Hub, Male 1 Usage
11 3234390 Bearing 3 Usage
11 3234390 Bearing 3 Usage
11 3234390 Bearing 3 Usage
12 ------- Spacer, Nylon 2 Usage
12 ------- Spacer, Nylon 2 Usage
13 ------- Hub, Machining, Male 1 Usage
14 ------- Bushing 2 Usage
15 2203728 Asm., Output Hub, Female 1 Usage
15 2203728 Asm., Output Hub, Female 1 Usage
16 ------- Hub, Machining, Female 1 Usage
17 2203730 Kit, Fasteners [Incl. 10 Screws] 1 Usage
17 2203730 Kit, Fasteners [Incl. 10 Screws] 1 Usage
18 2203729 Kit, Seal Repair [Incl. 2,4,19] 1 Usage
19 ------- O-Ring 1 Usage
20 3234407 Plate, Armature 1 Usage
21 2203733 Button, Thrust 1 Usage
22 2203734 Housing, Clutch 1 Usage
23 3234393 Kit, Roller [Incl. 20 Rollers] 1 Usage
24 3234466 Asm., Roll Cage [Incl. 25,26] 1 Usage
25 ------- Cage, Roll 1 Usage
26 ------- Clip, Spring 20 Usage
27 2203735 Asm., Gearcase [Incl. 28-32] 1 Usage
28 ------- Bushing 1 Usage
29 ------- Gearcase 1 Usage
30 ------- Fitting, Hose, 90 Degree 1 Usage
31 2203739 Plug, Fill [w/o O-Ring] 1 Usage
32 2203738 Plug, Drain 1 Usage
33 2203736 Asm., Input Cover [Incl. 17,19,34] 1 Usage
34 ------- Cover, Input 1 Usage
35 2203737 Asm., Pinion Gear [Incl. 11,36,37,38] 1 Usage
36 ------- Bearing, Ball 1 Usage
37 ------- Spacer, Pinion Cover 1 Usage
38 ------- Pinion 1 Usage
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post #4 of 9 Old August 20th, 2010, 01:53 PM
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Re: Front dif leaking out of drive shaft hole

I don't think you are going to be able to replace the seal without romoving the Diff from your car. It's not very technically difficult but labor intensive. You will need to remove both front axles which means removing the brake calipers from their discs, the main axle bolt and two washers, Tires of course, Hub, steering tie-rod @ wheel, top pinch bolt,swing down the bearing housing and pull out the axles. The diff is held by 4 bolts inn the bottom, Disconnect the vent tube and control wire and the most challanging the drift pin that is in the U-joint holding the axle in.
When you get it out I would buy the upgrade from Holz racing. It comes witht he seals and is an upgrade. Of course while you got it out you might want to repace the plastic inner cage with one of their Aluminium ones,
Be sure to use the Polaris fluid,
John
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post #5 of 9 Old August 20th, 2010, 02:59 PM Thread Starter
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Re: Front dif leaking out of drive shaft hole

Labor intensive....thats the easy stuff, I've become a pro at takin out axles and takin apart that aspect of it. I figured the hard part would be pulling the stuff out of the diff but it seems like the seal is right there. I am def. going to look into the holz upgrade.
Is it just #4 I need? Or 4& 5? Will I be able to tell easily if stuff is really worn when I open it up?
RZR only has 650 miles....75 hrs
Thanks a lot for your help so far John.
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post #6 of 9 Old August 20th, 2010, 03:01 PM
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Re: Front dif leaking out of drive shaft hole

I think you need #2.
The Holz pinion flange replaces #34: http://www.holzracingproducts.com/sh...ont-diff-p-769
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post #7 of 9 Old August 20th, 2010, 05:24 PM
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Re: Front dif leaking out of drive shaft hole

You know what gets me ... the drive shaft from the transfer case to the front diff ... the u joint ends are out of phase from Polaris ... so it cant be balanced. And with that little bearing/seal retainer is so weak on the factory front diff ... how does the seal not fail more often! That drive shaft has to put a weird vibration on it

I went with the Holz bearing retainer and balanced/re-phased drive shaft from Tower Works Fab ... knock on wood ... everything is in great shape!

2010 Class 2 Champion -World Off Road Champion Series - UTV #515
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post #8 of 9 Old August 21st, 2010, 05:13 AM Thread Starter
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Pissed Re: Front dif leaking out of drive shaft hole

Quote:
Originally Posted by Tuf-Skin View Post
The holz one come with #19 and #2 as well correct?
That cover that holds the o-ring and stuff in alone is $56 OEM. Can't even get a price without cling for the seal or o-ring. For $50 bucks I think I'll go with the holz. Now I just gotta figure out what I gota do about my large gash in my tire......I really hate that everytime I go ride this thing it's costing me $$$ besides gas!!
Still hella fun tho
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post #9 of 9 Old August 21st, 2010, 07:21 AM Thread Starter
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Re: Front dif leaking out of drive shaft hole

Is that the only kit/part I need to fix this leak?

-Zac
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