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front diff?

This is a discussion on front diff? within the Engine and Drivetrain forums, part of the Technical category; Hey guys Im a newbie here and also a newbie to the RZRs. Im having about a problem with my 09 800S LE. Sometimes the ...


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  #1  
Old May 23rd, 2012, 10:35 PM
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front diff?

Hey guys Im a newbie here and also a newbie to the RZRs. Im having about a problem with my 09 800S LE. Sometimes the 4x4 will kick in and sometimes it will not. It will show on the dash switch its on and also on the instrument panel that its on but the front will not be pulling but sometimes it will be. Tonight when I rode the 4x4 light on the instrument panel would come on for a minute then go off and sometimes it wouldnt even come on when I flipped the switch for it to come on. What could this be?

Last edited by Tuf-Skin; May 24th, 2012 at 03:39 PM.
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  #2  
Old May 26th, 2012, 05:44 PM
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Re: front diff?

Quote: Originally Posted by 09mustangman View Post
Hey guys Im a newbie here and also a newbie to the RZRs. Im having about a problem with my 09 800S LE. Sometimes the 4x4 will kick in and sometimes it will not. It will show on the dash switch its on and also on the instrument panel that its on but the front will not be pulling but sometimes it will be. Tonight when I rode the 4x4 light on the instrument panel would come on for a minute then go off and sometimes it wouldnt even come on when I flipped the switch for it to come on. What could this be?
I would check the plastic cage in the front differential. If the cage is cracked it will intermittedely engage or not engage at all. Quite common - it's a weak link in the drivetrain. A lot of guys that off road hard using 4WD ditch the plastic cage and go to an aluminum one........
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Old May 26th, 2012, 05:46 PM
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Re: front diff?

If your not familiar with the plastic cage in the front diff look up "RZR 900 front diff" on YouTube. Shows a full disassembly of a broken plastic cage with a new replacement.......
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  #4  
Old May 29th, 2012, 04:08 PM
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Re: front diff?

mustangman,

There probably isn't anything wrong with your machine. Being a newbie you may not know that the front diff in a RZR is a Hilliard "overunning" differential.

By design the front axle only engages when the rear wheels slip. I've done a number of replies to posts on how it works.

But reality is you can't "engage AWD" with the flick of a switch.

I ride the Colorado Rockies, Utah mountains and Moab. I've got 4000 miles on my machine and I'll bet I don't have 1 mile with the front axle engaged. That is by design of Polaris.

Pirate
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Old May 29th, 2012, 05:32 PM
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Re: front diff?

Quote: Originally Posted by Pirate View Post
mustangman,

There probably isn't anything wrong with your machine. Being a newbie you may not know that the front diff in a RZR is a Hilliard "overunning" differential.

By design the front axle only engages when the rear wheels slip. I've done a number of replies to posts on how it works.

But reality is you can't "engage AWD" with the flick of a switch.

I ride the Colorado Rockies, Utah mountains and Moab. I've got 4000 miles on my machine and I'll bet I don't have 1 mile with the front axle engaged. That is by design of Polaris.

Pirate
No doubt your differential does not automatically engage when you switch to AWD. Ive broke cages and ran with cracked cages in my Sportsman's and RZR and it's very noticeable when you encounter rear wheel slippage and are waiting for AWD to engage and it does not. I've noticed while plowing with a damaged cage that when experiencing rear wheel slippage AWD would engage - but took a lot of slippage or me jumping on the gas to engage. Finally when it broke - no AWD at all of course. I have just over 3000 miles on my RZR. Mine probly has quite a few miles on it in AWD due to plowing. I've noticed while plowing, especially in icy conditions, that when in AWD the front tires engage when the rear wheels slip - but do not immediately disengage when the rear tires stop spinning. I have a very long driveway and when I drop the blade, slip, and the AWD engages - it stays engaged even going downhill. If I let off the gas it will disengage. The Hillard by design will only engage with rear wheel slippage - but when the roller are pulled up from the cage to lock the differential they don't immediately drop back into the cage when the rear wheels stop spinning WHEN under a constant torque load. I had a 96 Sportsman and 97 Scrambler that had the old Hillard hubs. Those worked exactly the same way, you just had 2 cages to worry about breaking - haha. If you had one bad cage in that set up, you were in for a hell of an immediate sharp turn when only one tire engaged
I blew apart several cages in my 06' 800 Sportsman until I ditched the plastic cage and went to an aluminum one. No more broken cages, just axles and CV's. maybe its the lift kit and 28" tires and 3 foot deep mud holes
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Old May 29th, 2012, 07:53 PM
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Re: front diff?

Hmmm...I'd bet it was the 3 ft mud holes...

I tromped through more mud as a kid on the farm than I ever want to remember. So I avoid 'em out on the trail. No broken axles or CV's...gotta be the mud!!! LOL

Pirate
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