Differential fill plug broke using torque wrench! - Polaris RZR Forum - RZR Forums.net
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post #1 of 9 Old May 20th, 2017, 04:28 PM Thread Starter
 
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Differential fill plug broke using torque wrench!

I am always very cautious when using plugs in aluminum. When changing my differential fluids I always use a torque wrench on all the plugs. For some reason my fill plug broke using the specified torque of 40- 50 foot pounds. I've run the service manual multiple times, do I have the torque right?

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post #2 of 9 Old May 20th, 2017, 05:05 PM
 
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Re: Differential fill plug broke using torque wrench!

The manuals are mis-printed. Many people have done just as you have. Alot of people say the torque should be 40-50 in-lbs.

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post #3 of 9 Old May 20th, 2017, 05:07 PM
 
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Re: Differential fill plug broke using torque wrench!

Also the new diff I put in mine had a steel fill plug instead of aluminum.

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post #4 of 9 Old May 20th, 2017, 08:33 PM
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Re: Differential fill plug broke using torque wrench!

That really sucks to have a mistype in the service manual. Its an easy trap to fall into if in a rush to get things done.
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post #5 of 9 Old May 23rd, 2017, 04:51 AM
 
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Re: Differential fill plug broke using torque wrench!

Damn bro i cant believe you didn't question that when you read it. Not your fault and they should have did a better job with the manual but the clutch on the engine side is only 40 ftlbs and that's an important fastener for instance.

If you didn't crack the case id see if maybe u go up a size and using a steel one and plenty of lube cut new threads or what you'll end up doing.

For future reference if it's something important i torque to spec otherwise I use the German torque specs "GUTEN-TITE" LOL

Best of luck and please post what the fix ends up being im very curious.
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post #6 of 9 Old May 23rd, 2017, 05:46 AM
 
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Re: Differential fill plug broke using torque wrench!

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Originally Posted by Rzr800s2009 View Post
Damn bro i cant believe you didn't question that when you read it. Not your fault and they should have did a better job with the manual but the clutch on the engine side is only 40 ftlbs and that's an important fastener for instance.

If you didn't crack the case id see if maybe u go up a size and using a steel one and plenty of lube cut new threads or what you'll end up doing.

For future reference if it's something important i torque to spec otherwise I use the German torque specs "GUTEN-TITE" LOL

Best of luck and please post what the fix ends up being im very curious.
No need to go up in size or anything, it just breaks the outer flange off the plug. Simply take it out and put in a new plug.

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post #7 of 9 Old May 23rd, 2017, 08:43 AM Thread Starter
 
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Re: Differential fill plug broke using torque wrench!

I feel like an idiot for over tightening the plug. I knew the torque seemed excessive but assumed it was necessary for a reason. The thing that really burns me is there is no mention of the misprint from Polaris and I can see any revised specification posted anywhere.
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post #8 of 9 Old May 23rd, 2017, 09:08 AM
 
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Re: Differential fill plug broke using torque wrench!

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Originally Posted by aswetich View Post
I feel like an idiot for over tightening the plug. I knew the torque seemed excessive but assumed it was necessary for a reason. The thing that really burns me is there is no mention of the misprint from Polaris and I can see any revised specification posted anywhere.
Yea I've never seen Polaris mention that the torque was wrong either. And I'm not 100% on the 40-50 in-lbs either. But after reading about so many broken plugs I just tighten mine up nice and snug so it wont back out. No problems in 2500 miles, just keep an eye on it for a bit after you do fluid changes.

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post #9 of 9 Old May 23rd, 2017, 09:57 AM
 
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Re: Differential fill plug broke using torque wrench!

Good and snug is all you need, it has an O-ring seal, 40-50 ft. lbs. is way excessive!
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