Having the same problem so hopefully there will be some knowledgeable responses.

 

Buy the newest 900 XP RZR front diff you can new from Polaris and install it.

It will bolt right in. It may require a bit of grinding on the bottom of the steering rack bracket depending on the year of your 800.

But that differential will come with the billet aluminum sprague, as well as the “halo-ed” ring gear.

The only stronger option is to swap the diff mounting plate using a Gilbert designs plate and run an XP1K front diff. But that means your front diff will be running a faster ratio then your rear. Which does sort of work but you won’t like it.


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Thanks for the suggestion, sounds like a good solution.
Regards,
Ron

 

The other alternative, and what I’m looking at is the HDP billet case front diff from #SATV

 

So I have a damaged front diff from a 2010 rzr 800s model number 1332831. Polaris Part Number 1332803 replaces OEM Part Numbers (edited... 1332438* [which I have, damaged], 1332842, 1332803, 1332831, 1332842, and 1334309.)

My question is where did you find the compatibility references? I haven't been able to find that same info.
I purchased a Trailsport Motors "Heavy Duty Upgraded Front Differential Gear Case", which munched itself in 300 miles of easy trail driving, after the original lasted over 5,000 miles. Since it's been over 30 days since delivery, it's off the warranty. It hasn't been removed from the car yet, but draining it yielded a dozen steel chips, which I suspect are from the cage of the Sprague Carrier.

 

I cannot remember exactly where I found the compatibility references right off hand, that was 11 months ago). It was a combination of places I was searching online.

I had seen the upgrade (1k front diff) from Gilbert Designs but chose not to replace the front diff at that time because I did not want to replace something not broken yet. Although I did go ahead and install the Gilbert Design upper and lower gussets.

I ended up with Superatv front diff. I did have to do a little bit of grinding to the steering rack. As of so far, I have been running it with no problems ever since.

 

I cannot remember exactly where I found the compatibility references right off hand, that was 11 months ago). It was a combination of places I was searching online.

I had seen the upgrade (1k front diff) from Gilbert Designs but chose not to replace the front diff at that time because I did not want to replace something not broken yet. Although I did go ahead and install the Gilbert Design upper and lower gussets.

I ended up with Superatv front diff. I did have to do a little bit of grinding to the steering rack. As of so far, I have been running it with no problems ever since.

First of all....thank you for updating progress on your dilemma (lots of forums you never see final results or findings)

I'm dealing with the Boss's 2010 rzr 800 with a grenaded front diff (no chance of rebuild) and after countless dead ends with the 1332803 OEM assembly number, your post here has been a light at the end of the tunnel.

Question: did you go with the 1334309 as stated? (that number crosses easily to a bunch as well) I have to pull the trigger on an assembly very soon. Hopefully you can confirm!

Thanks!

 

Sorry for the slow reply...
I am running a 1334309 front diff made by superatv.
Yes, there is a lot of numbers that cross reference. You have a lot of options for the front diff. You can put a front diff from a 1000 model or a beefed up aftermarket company.
You can add gussets from Gilberts designs as well.
You will need to do a little bit of grinding to fit newer, larger front diffs around the steering rack.
thanks
nick

 

Update:

The Local distributor up here was able to source an equivalent in aftermarket for the 1334309. Quoted a few weeks. That kept getting bumped back +2 weeks every 2 weeks. From mid May to end of July.......

Got fed up and ordered an East Lake Axle Diff301 for like 550 USD -

Once exchange, shipped and customs stuff, it was at my doorstep on the 3rd business day and all said and done (with a jug of local sourced Demand Drive fluid) for $972 CAD. Which is a bit cheaper than the one getting back order extended over and over.

It fit like all the info for the 1334309 said it would - trim the front frame and rack n pinion support areas.

Installed, tested, me and the owner are happy.

(Thought Id share my Canadian experience)