XP to RZR front differential swap - Page 2 - Polaris RZR Forum - RZR Forums.net
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post #16 of 159 Old March 21st, 2013, 10:32 AM
 
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Re: XP to RZR front differential swap

Your calling the cage the aluminum housing? I'm assumming after reading that the difference in the housings are one (900) is thicker than the (800)? I currently have a 900 rzr xp4 and shattered the housing this past weekend and am looking for a replacement to carry with me. I have noticed the 800's are more available and less expensive. Warranty is supposed to cover my stock one but the breakage put me out of commision. If I would have had a spare I could have been rolling again.
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post #17 of 159 Old March 21st, 2013, 11:10 AM
 
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Re: XP to RZR front differential swap

the aluminun housings are the same ..
Look at the links i gave you
the part numbers for the the cover and housing for the xp and 800 are the same

Kit, Gearcase Asm. [Incl. Hose Fitting, [+]
3235172

Asm., Cover Output [Incl. O-Ring, Dowel [+]
3235168


what i am talking about is the cage inside

Asm., Billet Roll Cage [Incl. Roll Cage, [+]
3235262 --- this is the xp


Asm., Roll Cage, Zn [Incl. Roll Cage, [+]
3235261 --- this is the 800


all the rest are the same part numbers
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post #18 of 159 Old March 21st, 2013, 11:55 AM
 
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Re: XP to RZR front differential swap

Fun4,

It would be interesting to see what you find in the shattered housing. A lot of what has been seen, and I have one in the shop, is that the pinion nut comes loose, the pinion moves deeper into the ring gear, gets wedged and then the rotation forces the pinion down and shatters the housing.

Would be interesting to see what caused yours. Pictures maybe?

Thanks,

Pirate
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post #19 of 159 Old March 21st, 2013, 12:04 PM
 
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Re: XP to RZR front differential swap

Quote:
Originally Posted by Pirate View Post
Fun4,

It would be interesting to see what you find in the shattered housing. A lot of what has been seen, and I have one in the shop, is that the pinion nut comes loose, the pinion moves deeper into the ring gear, gets wedged and then the rotation forces the pinion down and shatters the housing.

Would be interesting to see what caused yours. Pictures maybe?

Thanks,

Pirate
mine was the ring gear teeth were torn off ... i missing around 4 teeth .. all chewed up ... Nut was tight taking it apart ...
was almost as much to buy ring and pinon kit then a complete new one ..
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post #20 of 159 Old March 21st, 2013, 12:14 PM
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Re: XP to RZR front differential swap

i see some confusion with some answers here.... first 08-10 800 vs a xp 900 front diff they are differant the xp is larger and as said it will fit with some triming wile your 11 800-4 may be the same this doesnt mean all are also is a non 4 2011 the same? it could be they put the bigger diff in the 4 seaters.

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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post #21 of 159 Old March 21st, 2013, 12:16 PM
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Re: XP to RZR front differential swap

My understanding is that to run a 2011+ diff in a 2008-2010, you need to also shorten the propshaft, or replace it with the later one.

We ordered all the parts to do this in a 2009 RZR S, just waiting for them to show up to make sure it is that simple.

I found this thread when researching this, it has some good photos:

https://www.rzrforums.net/engine-driv...f-changes.html

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post #22 of 159 Old March 21st, 2013, 12:29 PM
 
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Re: XP to RZR front differential swap

Quote:
Originally Posted by johnnycat8 View Post
i see some confusion with some answers here.... first 08-10 800 vs a xp 900 front diff they are differant the xp is larger and as said it will fit with some triming wile your 11 800-4 may be the same this doesnt mean all are also is a non 4 2011 the same? it could be they put the bigger diff in the 4 seaters.
the parts i listed are for the 2 seater ... 2010 and up xp,2 seater 4 seater are the same ... excatlly the same except for the cage inside.

The 2009 and down are different , totaly different but i too have read on here that they can be used in a 2010 up ..
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post #23 of 159 Old March 21st, 2013, 12:39 PM
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Re: XP to RZR front differential swap

Quote:
Originally Posted by jamies123a View Post
Quote:
Originally Posted by johnnycat8 View Post
i see some confusion with some answers here.... first 08-10 800 vs a xp 900 front diff they are differant the xp is larger and as said it will fit with some triming wile your 11 800-4 may be the same this doesnt mean all are also is a non 4 2011 the same? it could be they put the bigger diff in the 4 seaters.
the parts i listed are for the 2 seater ... 2010 and up xp,2 seater 4 seater are the same ... excatlly the same except for the cage inside.

The 2009 and down are different , totaly different but i too have read on here that they can be used in a 2010 up ..
i know all the xp are the same i was talking about the 800 you said your 800 diff is the same as the xp.

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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post #24 of 159 Old March 21st, 2013, 12:41 PM
 
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Re: XP to RZR front differential swap

Quote:
Originally Posted by Pirate View Post
Fun4,

It would be interesting to see what you find in the shattered housing. A lot of what has been seen, and I have one in the shop, is that the pinion nut comes loose, the pinion moves deeper into the ring gear, gets wedged and then the rotation forces the pinion down and shatters the housing.

Would be interesting to see what caused yours. Pictures maybe?

Thanks,

Pirate
This is the only pic that I will have due to it being under warranty. I couldnt get in there to get a really good pic. Hopefully it loads.Click image for larger version

Name:	rzr differential.JPG
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post #25 of 159 Old March 21st, 2013, 12:41 PM
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Re: XP to RZR front differential swap

Quote:
Originally Posted by jamies123a View Post
Quote:
Originally Posted by johnnycat8 View Post
i see some confusion with some answers here.... first 08-10 800 vs a xp 900 front diff they are differant the xp is larger and as said it will fit with some triming wile your 11 800-4 may be the same this doesnt mean all are also is a non 4 2011 the same? it could be they put the bigger diff in the 4 seaters.
the parts i listed are for the 2 seater ... 2010 and up xp,2 seater 4 seater are the same ... excatlly the same except for the cage inside.

The 2009 and down are different , totaly different but i too have read on here that they can be used in a 2010 up ..

I believe that 2008 and 2009 are the same, in 2010 they added the metal carrier but kept the same housing, and in 2011 they completely changed the housing.

Here are the parts diagrams from Polaris:

2008-2009:


2010:


2011-2013 800:


2011-2013 XP(including jagged X:

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post #26 of 159 Old March 21st, 2013, 12:44 PM
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Re: XP to RZR front differential swap

Quote:
Originally Posted by American Rock Rods View Post
My understanding is that to run a 2011+ diff in a 2008-2010, you need to also shorten the propshaft, or replace it with the later one.

We ordered all the parts to do this in a 2009 RZR S, just waiting for them to show up to make sure it is that simple.

I found this thread when researching this, it has some good photos:

https://www.rzrforums.net/engine-driv...f-changes.html
according to hawk the diff change is in 2011 not 2010 and trust me hawk knows his stuff

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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post #27 of 159 Old March 21st, 2013, 12:46 PM
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Re: XP to RZR front differential swap

Quote:
Originally Posted by American Rock Rods View Post
Quote:
Originally Posted by jamies123a View Post
Quote:
Originally Posted by johnnycat8 View Post
i see some confusion with some answers here.... first 08-10 800 vs a xp 900 front diff they are differant the xp is larger and as said it will fit with some triming wile your 11 800-4 may be the same this doesnt mean all are also is a non 4 2011 the same? it could be they put the bigger diff in the 4 seaters.
the parts i listed are for the 2 seater ... 2010 and up xp,2 seater 4 seater are the same ... excatlly the same except for the cage inside.

The 2009 and down are different , totaly different but i too have read on here that they can be used in a 2010 up ..

I believe that 2008 and 2009 are the same, in 2010 they added the metal carrier but kept the same housing, and in 2011 they completely changed the housing.

Here are the parts diagrams from Polaris:

2008-2009:


2010:


2011-2013 800:


2011-2013 XP(including jagged X:
ok it shows 2010 as the smaller diff still so the larger is a 2011 and up thing... alot of internal changes for the better too huge size increas on the pinion bearing that was a weak spot

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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post #28 of 159 Old March 21st, 2013, 12:47 PM
 
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Re: XP to RZR front differential swap

Quote:
Originally Posted by johnnycat8 View Post
Quote:
Originally Posted by American Rock Rods View Post
My understanding is that to run a 2011+ diff in a 2008-2010, you need to also shorten the propshaft, or replace it with the later one.

We ordered all the parts to do this in a 2009 RZR S, just waiting for them to show up to make sure it is that simple.

I found this thread when researching this, it has some good photos:

https://www.rzrforums.net/engine-driv...f-changes.html
according to hawk the diff change is in 2011 not 2010 and trust me hawk knows his stuff

sorry you are right i meant to say 2011 and up ... 2010 and down are differnt ... just look at the part numbers and you can see for yourself...
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post #29 of 159 Old March 21st, 2013, 12:50 PM
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Re: XP to RZR front differential swap

The polaris parts catalog has all of those diagrams, plus exploded views of each different differential. There are some cool things to learn by studying the differences.

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post #30 of 159 Old March 21st, 2013, 12:51 PM
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Re: XP to RZR front differential swap

Quote:
Originally Posted by jamies123a View Post
Quote:
Originally Posted by johnnycat8 View Post
Quote:
Originally Posted by American Rock Rods View Post
My understanding is that to run a 2011+ diff in a 2008-2010, you need to also shorten the propshaft, or replace it with the later one.

We ordered all the parts to do this in a 2009 RZR S, just waiting for them to show up to make sure it is that simple.

I found this thread when researching this, it has some good photos:

https://www.rzrforums.net/engine-driv...f-changes.html
according to hawk the diff change is in 2011 not 2010 and trust me hawk knows his stuff

sorry you are right i meant to say 2011 and up ... 2010 and down are differnt ... just look at the part numbers and you can see for yourself...
is the diff conector the same still ??? thats alot better diff but i also saw a brok one on here last night first one too this seems like a good upgrade for a older rzr or the turbo guys

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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