Rear Diff helicoil - Polaris RZR Forum - RZR Forums.net
RZR 800 Specific Discussion Discussions dedicated to the standard RZR 800 50 model

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post #1 of 13 Old June 3rd, 2017, 04:49 PM Thread Starter
 
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Rear Diff helicoil

While changing the oil last season, i stripped out the Helicoil for the rear differential drain plug. Does anyone know what size the replacement would be?
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post #2 of 13 Old June 4th, 2017, 12:55 AM
 
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Re: Rear Diff helicoil

Not sure but maybe you can go up in size instead?
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post #3 of 13 Old June 4th, 2017, 07:43 AM
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Re: Rear Diff helicoil

What model & year RZR?

The my RZR 800 does not have HeliCoils.

2014 800 LE w/EPS 50
PRO ARMOR trail doors, RYFAB rear windshield, MotoAlliance Fire Storm cab heater, RYFAB cargo rack, WARN PV4500S wide spool winch, POLARIS front windshield and top, 2008 tail lamp assemblies with backup lights, RACERTECH 2 lift, Duraclutch, R2C Air Filter, Garage Products A-arm bushings.
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post #4 of 13 Old June 4th, 2017, 11:40 AM Thread Starter
 
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Re: Rear Diff helicoil

its a 2009 800
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post #5 of 13 Old June 4th, 2017, 01:56 PM
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Re: Rear Diff helicoil

Did the HeliCoil strip out, or did it just unscrew with the plug?

If it is the stock drain plug, the thread size is 3/8-24 SAE Straight Thread O-ring (O-Ring Boss). You may be able to pick up some 3/8-24 HeliCoils and re-install one in the differential.

2014 800 LE w/EPS 50
PRO ARMOR trail doors, RYFAB rear windshield, MotoAlliance Fire Storm cab heater, RYFAB cargo rack, WARN PV4500S wide spool winch, POLARIS front windshield and top, 2008 tail lamp assemblies with backup lights, RACERTECH 2 lift, Duraclutch, R2C Air Filter, Garage Products A-arm bushings.
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post #6 of 13 Old June 4th, 2017, 02:44 PM
 
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Re: Rear Diff helicoil

It sounds like it's been cranked on before. You might need to use a product like this:

https://autoplicity.com/2546839-dorm...FQVqfgodaaAJNQ

Or, what I've done is just get a short bolt that's big enough to screw into a larger drilled and tapped hole in the differential, and before installing, I drill and tap a hole in the middle of the bolt to make one similar to the one I posted above.

Good luck!
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post #7 of 13 Old December 4th, 2017, 04:38 PM
 
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Re: Rear Diff helicoil

Hey guys, my rear diff drain plug is also stripped. I don't have my repair manual around. Does anyone know if the plug is also a 3/8-24 standard (as mentioned above for the 2009) so I can purchase a Time-Sert kit to repair mine? I have a 2013 800 4 EPS.

thanks.
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post #8 of 13 Old December 5th, 2017, 12:46 AM
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Re: Rear Diff helicoil

Drain plug part number 5133731 is listed for RZR 800 rear diff from 2008 thru 2014.
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2014 800 LE w/EPS 50
PRO ARMOR trail doors, RYFAB rear windshield, MotoAlliance Fire Storm cab heater, RYFAB cargo rack, WARN PV4500S wide spool winch, POLARIS front windshield and top, 2008 tail lamp assemblies with backup lights, RACERTECH 2 lift, Duraclutch, R2C Air Filter, Garage Products A-arm bushings.
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post #9 of 13 Old December 27th, 2017, 09:05 PM
 
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Re: Rear Diff helicoil

Okay, I'm trying to figure out how to repair my rear diff drain plug with the Time-Sert, but there is not a lot of room to drill and retap. Has anyone done this and how did you do it with the limited space?
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post #10 of 13 Old December 28th, 2017, 07:31 AM
 
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Re: Rear Diff helicoil

Rob:
We did a pinion nut on one in Reno last winter, the plug was stripped. I tool a 7/16-20 tap and ran it in with out drilling, then we used a short 7/16 Allen head bolt with a nylon washer to seal it.
Les
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post #11 of 13 Old December 28th, 2017, 08:15 AM
 
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First Name: Rob
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Re: Rear Diff helicoil

Quote:
Originally Posted by Pullerguy View Post
Rob:
We did a pinion nut on one in Reno last winter, the plug was stripped. I tool a 7/16-20 tap and ran it in with out drilling, then we used a short 7/16 Allen head bolt with a nylon washer to seal it.
Les
Thanks Les. Can you explain how you did this?
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post #12 of 13 Old December 28th, 2017, 08:54 AM
 
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Re: Rear Diff helicoil

Quote:
Originally Posted by Pullerguy View Post
Rob:

We did a pinion nut on one in Reno last winter, the plug was stripped. I tool a 7/16-20 tap and ran it in with out drilling, then we used a short 7/16 Allen head bolt with a nylon washer to seal it.

Les


Did the same thing Les , I would dip my tap in heavy wheel bearing grease turn two or three turns then clean tap and repeat . Pulled the chips out really well


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post #13 of 13 Old December 28th, 2017, 02:35 PM
 
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First Name: Les
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Re: Rear Diff helicoil

Rob:
I used a taper tap so the starting size was small enough I didn't need to drill it out. After I had some good threads started I backed the taper out and used a plug tap to finish the threads the rest of the way. As Carl mentioned I used a bit of grease on the tap to collect the cuttings, I turned the tap about 1/2 to 3/4 turn then back off then advance a little more. Pulled it and cleaned after a couple of turns, then more grease and do it all over again.

One issue with using the plug with the drain in the center is clearance for the hex of the head.

Hope this makes sense.
Les
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