Polaris RZR Forum - RZR Forums.net banner

2011 RZR4 Rear Differential Internal Fail

168K views 801 replies 120 participants last post by  nibroc 
#1 ·
Hey all,
I have a 2011 RZR 4 that just blew out the rear differential. I was on the trail (easy trail), I heard a bit of grinding, stopped looked around at everything and couldn't see anything wrong. Got going again and then it failed completley, something internal gave and punctured the case, dumping all the oil. Its only 8 months old, well taken care of, never driven overly hard and all the maintenance is kept up. I checked all the oils before heading out. Has anyone else had this problem or known someone who has? Anyone know of polaris covering this if the factory warranty is expired by about 4 months? Any help/info would be awesome...Thanks!
 
#8 ·
I'm certain I can fix it myself, I have the service manual for it and it gives pretty good instructions on how to change it. Problem is the cost of parts...at a minimum I'm going to pay $650-$700 for a new case not including whatever it broke or damaged inside the case. A completly new assembly I've found for as low as $1150 and up. I shouldn't have this problem on a machine that is less than a year old.

I hoping to convince Polaris to pay for it since it was obviously mechanical failure. Probably won't happen but its worth a try. I'm curious, though, how many other people have had this same problem. I know I've heard that its happend on 2010 models from other dealerships.
 
#9 ·
have a 2012 4 that only had 144 miles on it. Going on a logging road. with 3 people in it. Grinding then a bump. knocked out a whole in the case. Lucky me it was still under warrenty. They just threw a new tranny in it. It was not road hard, and it was an internal problem! Good luck if you need a second case to fight your case, you can PM me.
 
#12 ·
Look familiar

2011 rzr4 low miles, low hours, bought it used but in mint condition i doubt any previous abuse?
I have done a little web research, seems as though the pinion nut backs off and then the pinion jams between the case braking it in half.
Just got mine back going $1300.00 later.
Installed new diff myself to save labor.
For what its worth it looks like all years of the rzr-s have the updated, same part number for the rear diff.

 
#15 ·
Babbitsonline.com
1332889 ASM-GEARCASE,COMPLETE $1,229.13 includes the rear diff and tranny
or you can buy just the rear diff for:
3235281 ASM-CARRIER (026CA111X) $1,141.33
It's crazy I know but this is how it is. Lots of people on here are always looking for a tranny. Get some of that money back.
I paid around 1,500 from my dealer installed and then sold the tranny for $900 to a dude in Louisiana from the forum.
:ride:
 
#19 ·
So I was building a new skid plate for mine this week and I noticed that the new transmission was leaking a little bit of fluids. (my transmission blew up as 144 miles) So I take it back into the dealer, who has been great. They said they would take care of it. Just got of the phone with the dealer. They said it looks like machine that puts the sealant on must have trean out of sealant at the end and left a 1/4 gap. This is 2012 4 btw
 
#20 ·
Betwenn me and y buddies we have three 2012 rzr 4's both of them have lost the rear end exactly the same way.....I think I will just sell my RZR and get a Teryx before mine goes out.
Unless any body knows a way to keepit from happening.
 
#26 ·
Blew my rear diff yesterday. Just like these other guys in this thread. I mean the pics look exactly like mine. 2011 RBE 4 seater. 1100 easy miles. We were just riding along about 15mph and loud grinding sound skidded to a stop. Broke the pinion and knocked a hole in the case. I was about 15 miles in the middle of the woods. Luckily I still had front wheel drive so I made it back to the truck. Lots of ugly sounds from the rear diff but Im glad it pulled me out of the woods.
Anybody get Polaris to do anything about this? All my roller bearings are out of the cage so I assume the pinion nut backed off and snap. I'll know more after I tear it apart.
 
#28 ·
After further inspection it is obvious my pinion nut backed off causing the failure. I have a brand new rear diff coming. Anybody got any suggestions of what to do to the new one to keep this from happening again? I had thought about using green loctite on the new pinion nut, but I have read that the loctite will eat the nylon insert up. I have even thought about a small spot weld or using a punch to mar the threads so the nut cant back off again. I know that sound crazy but if it happens again the pinion gear will be broken in half anyhow.
Any ideas.
 
#31 ·
I don't remember what year Polaris made the change, but they used to set the nut with a punch, damaging the threads like you are talking about. Later they changed to the nylock version. You aren't supposed to reuse the nylock nut.

The HPD heavy duty case comes with instructions saying you can use lock tite... Don't remember what type of lock tite though.
 
#32 ·
Ok so been reading everyones comment and was wandering since mine had not broke YET is there anything to do to prevent breakage. I hear alot about the pinion nut backing out so what should i look for. Is it noticeable or something that needs to be checked by torque wrench. Thanks
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top