Those washers are the shims. I have never done gears in an ATV, but if it's anything like doing it in a car/truck you're really gonna want to know what you're doing to get it right.

 

The shims the OP is referring to, are not for the gears themselves. They are for the mounting of the diff to the coupler tube.

 

If you installing a new rear diff, save yourself some work and heartache, go ahead and replace the oem nyloc pinion nut with a solid steel nut from a 700 ranger and use loctite 272 to keep it from EVER coming loose again. As for the shims, my 800 diff didnt have any shims that I could ever find, some do, some dont. Best advice I could give would be to mount the diff up with all the bolts snugged up, except leave out that top coupler tube bolt. Then if there is room, try to get a feeler gauge down in there and see if you need to shim between the diff and coupler tube.

 

Do you know if that problem was corrected in the new rear differentials? It looks like the old ones were made by spicer and the new ones are made by Schaffer driveline.

 

I know for fact the nyloc nut problem was not fixed in the newer diffs. I had to replace my diff in April of 2016, the new one still had the nyloc nut. So I strongly suggest you take care of it now, before installing. Will save you from either pulling it out to replace the nut or even worse replace the diff again.

 

Alright I will take care of it before the install. Any good place to get the parts needed?

Tools required for the job? I have done some forum searches and my torque wrench won’t do the required 200+ foot pounds and also what socket trembles the nut?

Thanks

 

My torque wrench won’t do the required 200+ foot pounds.....

Thanks

There is the formula to get you to the 250 lbs needed. It uses the length of Puller Guy's tools with your torque wrench length to give you the setting for your torque wrench.

 

Where are you located? There are tools scattered all over at this point. If you will PM "Pullerguy" he has a database of where tools are, he also has loaner tools that he can send you. Here is the thread on swapping the pinion nut. http://www.rzrforums.net/rzr-800-sp...c-discussion/261873-razor-800-pinion-nut-repair-video-les-hansen-pullerguy.html
The oem parts needed are listed in the 2nd post of that thread also.

 

I am located in Saint Petersburg Florida and I will go ahead and get those parts ordered and send him a message. Thanks for all the information.

 

The shim (spacer) is item 16 on diagram.

It goes between the mounting bracket (7) and the the connector tube (3).
The spacer on my RZR is .015" thick.
It looks like the easiest way to measure the gap would be to install bracket tight against transmission, and measure between bracket and connector tube BEFORE installing rear diff.

 

The shim (spacer) is item 16 on diagram.
View attachment 533082
It goes between the mounting bracket (7) and the the connector tube (3).
The spacer on my RZR is .015" thick.
It looks like the easiest way to measure the gap would be to install bracket tight against transmission, and measure between bracket and connector tube BEFORE installing rear diff.

Thanks for diagram, that makes more sense on where it goes. Really appreciate it.

 

Just an update, since I have been moving and all my tools are not available, took the brand new rear diff to the Polaris dealer to have them do the work of replacing nylon nut with the all metal pinion nut. They said they have done it before and should be done the next day. 2 weeks later, they can’t give me a straight answer on what they are doing with it and keep telling me it’s not ready. I am losing my patience my local Polaris shop and just want my rear diff back. Anyone on here I can just send the rear diff to get the work done properly? Thanks

 

Av8or91
I sent you a PM.
Les

 

125 ft-lbs
View attachment 548585

The extension and torque wrench must be in a straight line.

Go to this website, scroll down to extension calculator.
https://www.belknaptools.com/support-library/

 

Pete:
You need 125 ft. lbs. There is an app for android, called "Torqued" it is quite handy to have. There are app's for iphones also, I haven't used them though.

This information if for calculating the torque wrench setting with the use of an adapter.
TA: Torque Applied to fastner
TW: Torque Wrench Setting required
A: Lenght of Adapte
L: Length of Torque Wrench from center of drive to center of handle
TW = TA x L / A + L
Example:
250 lbs.ft torque reqired
18" lenght of Adapter
16" torque Wrench Length
250 x 16 = 4000 / (18 + 16 = 34) 4000 / 34 = 117.6 so torque wrench is set at 118 lbs.ft.
250 times 16 equal 4000, add 18 to 16 equals 34, divide 4000 by 34 equals 117.6 set torque wrench to 118 lbs.ft

 

Thanks guys .........that was what I had calculated ......just wanted to be sure

 

TW = (TA x L) / (A + L)