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post #31 of 41 Old February 12th, 2012, 11:15 AM
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Re: Sprague Carrier Replacement - VIDEO

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Originally Posted by CallingAllBobs View Post
Another update - I put on about 50 miles on heavy, muddy trails. Lot's of big logs and rocks. It was this environment that broke the plastic carrier and the new one is holding up great. At one point I came down pretty hard on spinning front wheels and cringed thinking I'd hear the dreaded ratchet sound. Nope. I only heard the sound of my RZR tearing forward through logs, rocks and mud! This is a great fix.
That "ratchet" sound is terrible to hear...Even with the billet sprague, sooner or later you will hear it again. I haven't seen a rzr not make that sound including the XP--its just the design of the hillard clutch but for some reason I'm begining to think that contaminated diff fluid greatly contributes to it...You can go on two or three hard rides and the front diff fluid will be black again with fine metal. There is a lot of wear going on in that front diff..The fluid needs to be changed much more often than what the manual calls for...
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post #32 of 41 Old February 12th, 2012, 03:24 PM Thread Starter
 
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Re: Sprague Carrier Replacement - VIDEO

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Originally Posted by jerrzr View Post
That "ratchet" sound is terrible to hear...Even with the billet sprague, sooner or later you will hear it again. I haven't seen a rzr not make that sound including the XP--its just the design of the hillard clutch but for some reason I'm begining to think that contaminated diff fluid greatly contributes to it...You can go on two or three hard rides and the front diff fluid will be black again with fine metal. There is a lot of wear going on in that front diff..The fluid needs to be changed much more often than what the manual calls for...
Thanks for the heads up. I'm not very disciplined at changing out the front diff fluid like I should be. I will be now...
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post #33 of 41 Old February 27th, 2012, 05:09 PM
 
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Re: Sprague Carrier Replacement - VIDEO

First off thanks for the video has really helped me working on mine.

Where the magnet is there is a small metal piece that goes over it and it seems there is some way to adjust the depth of the magnet - it can be seen on yours towards the end of the video when you are putting the top cover on the diff before testing.

Mine is loose - I have pinched the ends in bit in the vise so it will stay on, did your magnet stick up 1/4" or so? I think someone tweeked enough to push that metal piece up enough to just be grabbing on the sides. Is that normal? Do I need to adjust it back down?

Its red and can be seen in your video around the 8 min mark on the top piece in the left of the video.

Without clamping it a bit would would just fall off down in the diff - curious how it is supposed to go before I finalize putting it back together.

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Last edited by Baditude; February 27th, 2012 at 05:16 PM.
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post #34 of 41 Old February 27th, 2012, 06:21 PM Thread Starter
 
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Re: Sprague Carrier Replacement - VIDEO

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Originally Posted by Baditude View Post
First off thanks for the video has really helped me working on mine.

Where the magnet is there is a small metal piece that goes over it and it seems there is some way to adjust the depth of the magnet - it can be seen on yours towards the end of the video when you are putting the top cover on the diff before testing.

Mine is loose - I have pinched the ends in bit in the vise so it will stay on, did your magnet stick up 1/4" or so? I think someone tweeked enough to push that metal piece up enough to just be grabbing on the sides. Is that normal? Do I need to adjust it back down?

Its red and can be seen in your video around the 8 min mark on the top piece in the left of the video.

Without clamping it a bit would would just fall off down in the diff - curious how it is supposed to go before I finalize putting it back together.

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BUTTON-THRUST,DC(6203-42-037)
I went back to the source video files and clipped out the entire section where I re-installed the armature plate. Maybe this will help?



I have plenty of time on the new carrier and it's working as expected. Turns on and off when needed.
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post #35 of 41 Old February 27th, 2012, 06:56 PM
 
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Re: Sprague Carrier Replacement - VIDEO

nice video...thanks for sharing.
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post #36 of 41 Old February 27th, 2012, 07:54 PM
 
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Re: Sprague Carrier Replacement - VIDEO

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post #37 of 41 Old February 28th, 2012, 03:21 AM
 
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Re: Sprague Carrier Replacement - VIDEO

Quote:
Originally Posted by CallingAllBobs View Post
Quote:
Originally Posted by Baditude View Post
First off thanks for the video has really helped me working on mine.

Where the magnet is there is a small metal piece that goes over it and it seems there is some way to adjust the depth of the magnet - it can be seen on yours towards the end of the video when you are putting the top cover on the diff before testing.

Mine is loose - I have pinched the ends in bit in the vise so it will stay on, did your magnet stick up 1/4" or so? I think someone tweeked enough to push that metal piece up enough to just be grabbing on the sides. Is that normal? Do I need to adjust it back down?

Its red and can be seen in your video around the 8 min mark on the top piece in the left of the video.

Without clamping it a bit would would just fall off down in the diff - curious how it is supposed to go before I finalize putting it back together.

#21 2203733

BUTTON-THRUST,DC(6203-42-037)
I went back to the source video files and clipped out the entire section where I re-installed the armature plate. Maybe this will help?



I have plenty of time on the new carrier and it's working as expected. Turns on and off when needed.


Sure did - yours does not stick out at all, the red metal piece is flat. against the pushrod
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post #38 of 41 Old February 28th, 2012, 07:19 AM
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Re: Sprague Carrier Replacement - VIDEO

Its refreshing to see a guy with good mechanical ability, that really knows how to spin a wrench, use an air ratchet, a punch, volt meter power source, understands oil seals, etc...
Very nicely done.
Just curious what do you do for a living?

You might be able to save a step by removing less front end components, and still be able to weasel out the axles.

I recommend you pm a mod or admin and put this in the Wiki section. Your video is the best Sprague Carrier Replacement vid I've seen so far, by a lot.

jmo

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post #39 of 41 Old February 28th, 2012, 07:41 AM
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Re: Sprague Carrier Replacement - VIDEO

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Does anyone have an update on the 50" and S model carriers? Are they plastic like previous years or metal like the XP? Thanks for the time and effort on the video btw, well done!

Yoshman762
According to the parts manual they are zinc. Aluminum is listed as a "high performance accessory". The XP gets Billet Aum.



post #40 of 41 Old February 28th, 2012, 08:17 AM Thread Starter
 
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Re: Sprague Carrier Replacement - VIDEO

Quote:
Originally Posted by allcool View Post
Its refreshing to see a guy with good mechanical ability, that really knows how to spin a wrench, use an air ratchet, a punch, volt meter power source, understands oil seals, etc...
Very nicely done.
Just curious what do you do for a living?

You might be able to save a step by removing less front end components, and still be able to weasel out the axles.

I recommend you pm a mod or admin and put this in the Wiki section. Your video is the best Sprague Carrier Replacement vid I've seen so far, by a lot.

jmo
Thanks. I'm just a hack, really. I don't know how to do most things, but I do know I can figure things out! It's amazing what you can learn on YouTube and I'm grateful for folks who take the time to share knowledge. Just trying to do my part. I'm a business consultant and help companies run better.

Another member mentioned the same thing about removing less parts to get the axle out. It looks like you can disconnect the steering arm, lower shock mount and A-arm bolts and pull the whole thing forward? That would save the time of removing the brakes & caliper. I didn't consider that. Having done this once though, I could probably have that differential out in 20 minutes the next time. I think it took me a couple of hours the first time.

Last edited by CallingAllBobs; February 28th, 2012 at 08:29 AM.
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post #41 of 41 Old May 22nd, 2012, 02:32 PM Thread Starter
 
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Re: Sprague Carrier Replacement - VIDEO

Another follow-up.

As advised above (which I really appreciate) I changed the front diff fluid Saturday and was surprised at how contaminated it was. As predicted, fluid was dark and plenty of shiny metal particles. I actually changed it, drove around the house a couple of times and changed it again. I think that was a good call because I could see remnants of old fluid and some aluminum. After the second change, I drew some out through the fill port and it was very clear and clean. It will be interesting to see what happens on the next change to see if the wear keeps up at this rate.
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