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Leaking front diff seals

27K views 16 replies 13 participants last post by  rbell14  
#1 ·
At around 1000 miles my front diff seals on both sides starting leaking badly. The dealer replaced both seals under warranty. About 65 miles later both seals started leaking again. I took it back in to the dealer and they are going to fix the issue under warranty. Has anyone else ran into this problem, and what did the dealer do for you? I've read about some problems with bad machining tolerances of the front diff possibly being the issue. Has anyone else had success with the dealer replacing the entire diff under warranty?
 
#2 ·
More than likely your axle cups have groves. You can put speedy seals on axles or replace the cups. Or seat the seal at a different depth.
 
#3 ·
mine have been leaking since the 250 mile mark. changed 3 seals since. have 800 miles or so now and still leaking. haven't took it to the dealer because I don't trust them working on my stuff. I think they have a bad batch of cups. I change mine when the puddle starts. Im always seeing oil on the cv's. Tried different depths also, it may have helped, but still leak after a couple rides
 
#5 ·
My seals don't leak but I really don't know why they don't. My axles have a bunch of play where they go in the diff. It's been that way since almost day one. It's a year old now and about 1900 miles. May not have any fluid in the diff. Lol
 
#8 ·
Had same problem here. At dealer for 3rd time they say seals and bearing and clearances all look good. Funny my front diff and axle cups had demand drive fluid on them. Waiting on seal kit been on back order for 3 weeks. Im sure its still not fixed. If not im gonna drain fluid and beat on it till diff explodes. Then they wont have a choice to replace!!
 
#10 ·
The service guy called this evening and said that the fluid I'm seeing isn't diff fluid, but rather lubricant they used to assemble the seals and install the axles...do they really think I'm an idiot??? So they claim they cleaned it up and drove it for a while and didn't see anymore fluid on the axles. Then after all that they wanted 1 hour of shop rate for diagnosing nothing.....I told them I wasn't paying a cent! After arguing my case they agreed to eat the shop rate and told me to just drive it as is. Fine...I'll do just that and when the diff takes a shit because all the fluid has leaked out, they can replace the entire diff under warranty. I'm going to have them state in writing that the seals are not leaking and that I'm seeing things....I will give them no recourse to deny my future claim when it does lock up....gosh I HATE Polaris and the warranty crap they make us owners go through. I've owned 3 RZR'S and currently own my XPT and a 90cc quad....I'm thinking these will be my last!!! It's really sad that Polaris treats their owners like crap....
 
#11 ·
Same story here. Leaking front diff at 800 mikes now. I replaced the seal and it's still leaking. Seal looked good. No reason for it to leak. Grrrrr!
 
#12 ·
I have a 17 xpt and had similar axle leak issue, found it wasn't the axle seals leaking. The oil on mine was leaking from the inside of the axle cup and around the splines, nothing to do with the seal. Not sure if it is the best idea but as a temporary solution I used black silicone on axle splines where they go into the diff cup and no more leak... Keep in mind that the seal on these seals against the axle cup not the axle itself so the silicone I used has no way of getting into the oil or contaminating the diff.... I am positive others are leaking in the same place!
 
#17 ·
Seal and front diff are know to fail. I just had my entire diff replaced under warranty due to excessive where internally. My plug magnet was covered with metal after changing the fluid 3 times in two days to attempt to flush it all out.

I'd change that fluid often and that doesn't guarantee anything with this diff.