XP to RZR front differential swap - Page 11 - Polaris RZR Forum - RZR Forums.net
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post #151 of 159 Old October 1st, 2015, 08:52 PM
 
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Re: XP to RZR front differential swap

Nope, the front driveshaft's rear yoke is designed to slide back far enough to slip the front yoke off the front diff. So it goes quite a ways back.

Rather than PB, pump it with a grease gun until grease comes out both ends.

Then slide it back. Since you have the front diff out... you can pull the front driveshaft off the Trans output shaft, then clean the output shaft and the yoke.

Then put a coat of grease on the spines, slip the yoke on, then pump it with a grease gun until you start to see grease out the end... and you're set.

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post #152 of 159 Old October 1st, 2015, 09:12 PM
 
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Re: XP to RZR front differential swap

Cool. Thank you! You just boosted my confidence back up. I'll let you know when I get it to fit!
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post #153 of 159 Old October 2nd, 2015, 09:36 AM
 
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Re: XP to RZR front differential swap

Got it! It had to be hammered back but it's good to go now! The only thing that had to be done is a little grinding to the steering bracket.
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post #154 of 159 Old October 2nd, 2015, 01:44 PM
 
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Re: XP to RZR front differential swap

Michael,

One more thing...please go in and put your year and model RZR in your profile. Helps us help you.

At this point in your post...I don't see the first page...so I don't remember if you told us what you had or not...

Just sayin'

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post #155 of 159 Old October 2nd, 2015, 03:45 PM
 
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Re: XP to RZR front differential swap

Quote:
Originally Posted by Pirate View Post
Michael,

One more thing...please go in and put your year and model RZR in your profile. Helps us help you.

At this point in your post...I don't see the first page...so I don't remember if you told us what you had or not...

Just sayin'

Pirate
Gotcha! Thanks for all your help! I don't know what I would have done without it. BTW, I have a 2008 RZR 800. Bought it brand new September of 2007. I think the only thing still original on it now is the frame, motor, and transmission. Its a never ending project!
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post #156 of 159 Old October 2nd, 2015, 04:27 PM
 
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Re: XP to RZR front differential swap

I have an 09 RZR 800.

So you do have to do a bit of grinding on the steering rack brackets.

But look carefully and make sure there 1/8" clearance between the diff housing and everything else.

I seem to recall that I had to do some grinding two or three places to get clearance. I was amazed the diff housing is pretty soft, so where there wasn't clearance it grooved the housing just setting the wheels on the floor.

So look closely!

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post #157 of 159 Old October 3rd, 2015, 04:30 PM
 
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Re: XP to RZR front differential swap

Front diff grenaded on my 2009 RZR (non-S). Ive read everything posted previously so no questions about fitting. My ONLY question is regarding price. Since price went well above the $850 that was posted at the beginning of this thread, can anyone recommend someone?
Thanks,
Jim in AK
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post #158 of 159 Old October 3rd, 2015, 04:42 PM
 
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Re: XP to RZR front differential swap

Jim,

Yes, I can make a recommendation on fabulous Hilliard diff for your 2009!

Contact Jeff at http://www.jjandaracing.com/

He takes 2014 XP900 front diffs, brand new, the blueprints them to bring clearances from as high as 0.040" down to 0.0005". The blueprinting costs $100 extra....best money I spent.

You will get instructions on where to grind a bit off the steering rack brackets. But its not difficult. With the wheels off and the hub disconnected at the top, you can easily take the front diff in and out of the frame. That way you do can do the grinding, put the diff in the frame, check, remove, grind, install check, etc. Until you get a little clearance everywhere.

My diff was in good shape just very noisy when crossing a snow bank and the diff would engage, drop out, engage, drop out...all the way across. So I talked to Jeff, bought a blue printed diff and installed it. I yet to even here it engage or disengage, it just works!!

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post #159 of 159 Old January 10th, 2018, 09:52 PM
 
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Re: XP to RZR front differential swap

Every one-Have 2008 800 RZR and I finally need a front diff. What if anything has changed up until today for a retro fit? Last recommended was a 2014 XP 900 RZR diff with clearance work? Lots of general info. This is 2017 is there anything newer/better/stronger/updated that has come along for this swap? Will it fit as easy as the 2014? Will it work in the old 2008/800. Have you done it?
What other parts should Murphy have on hand to do this swap?
eg. new roll pin for pinion to drive shaft yoke? Polaris PN?
new rubber o ring for drive shaft? Polaris PN?
Part #'s for 4 new longer base bolts? Will grade 8 stuff work or be too brittle? If not what is the precise length? Does that include length for washers (grade8) or will they fit or work?
Please list them all or anything else that may break or disappear during the swap. It is a long way to the dealer here and we have special Canadian prices for everything it seems. Its an old drive shaft now so who makes the best parts for the best prices for universals etc? Thanks for any help you can give and happy new year Bri
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