Are you sure you're not overfilling the rear diff? They already run hot as it is, and if you have it too full it runs even hotter causing the oil to expand and it ends up forcing it out of the axle seal.

 

The condition you describe is the vent being plugged.

Not sure I understand why it would run hotter if over filled.

 

Hey Michael.

I`m going thru the same issue . We had a thread not too long ago, talking about this issue. Here`s a quote from member Big Guy on what he found. and it makes sense . .

"Well I figured out my problem I pulled out my rear diff and found that the bearings were sloppy. But the biggest problem was that the bearing race on the passengers side is pressed into a collar that is then recessed into the case. Well that collar was lose in the case. I crossed referenced with the newer RZRs and they changed the design in 2009. It appeaers to me that the collar should have a press fit not passive like it was. so what happened was the collar started to spin in the case and it being steel and the case being aluminum it wore out the case. So I am going to have a new colar machined to fit and replace the bearings and I should be good to go. "

Its not gonna be a cheap fix, but a definate maybe on the cause of our persistant leaky seals on the right side . .

Jamie

 

hint!!! also make sure the spring is on the inside of the seal no spring the seal isn't tight and when replacing make sure you dont distort the seal

 

Never have had a leaker... I have replaced them when replacing axles and I always coat the shaft and seal with oil before installing axle...

 

Hmmm . . All my gearbox n fueltank vents are run up to snorkle Hieght. . .Could be a collapse someplace . . Nicely played Hoser ..

 

Hoser, Overfilling the gearbox (any box/diff/tranny) increases friction between the viscous fluid and the gears which pass through them. This increases the temperature of the gears and the fluid. Oil is not as heat conductive as air thus less air space in the box = less conduction of heat to the case and surrounding atmosphere. Basically it heat soaks the interior of the box which causes seal failure and also premature failure of gears which expand in response to the excess heat and increase the pressure at the pressure angle of the respective gears. This has the effect of "squeezing" the oil film at the pressure angle thus increasing wear/friction/heat. When I raced formula cars which used a transaxle the oil fill level was critical. A slight overfill heated up the gearbox greater than a moderate underfill. This was confirmed with real data obtained from thermocouples feeding temp. data to our MOTEC logger. The mechanics described above were related to me by my engineer who had experience with indy cars and ALMS prototypes.

Robin A.

Also your comment about a plugged vent is right on target. Caveat--Look for the simple things first (as you have said often) rather than throwing parts at the symptoms rather than the cause.

 

What kind of temperature increases we talking here hundreds of degrees, hot enough to change the tolerances of steel accelerate wear of seals designed for thousands of miles in hundreds of miles?

Sounds like a great theory might apply to a formula car doubt it applies to a low power, low stress RZR.

I have seen others comment about rear differential temps on this site so on my last trip I kept track of my rear diff temps after doing something high stress I got out held my hand on the case was just slightly warm.

High stress meaning like climbing up "P" mountain in Parker AZ or running 40-50 mph for 15 miles in soft sand gravel.

I have been slightly over filling my manual transmission transfer cases and differentials for 30 years majority of these machines see over 200k miles never a problem, well I did change one rear axle seal the other day that was leaking but the rear axle is a 1976 and it was the original seal, one rear axle seal on my 1987 school bus was weeping so I over filled the rear diff for my last 5000 mile trip and it quit leaking all together.

I guess if my stuff had 800 HP and I drove them 200 mph I might find different results.

 

I have an 08' that had a leaky passanger side rear seal. I guess it was a flaw from the factory so they came out with a new seal (I think its orange) to replace it. I put the new one in probably two years ago and havent had a problem since.

 

I soo wish that was all it was to it Sandaddict . . Me n Hivoltage have had the orange ones all along.

BUT ! I did go out to the rig, and find some collapsed vent lines where they route near the head n headers. Soo we`ll see what replacement of those brings opcorn:

 

i have all my diffs vents ran up and I installed bellows off a phoenix 200 on them. But they were leaking before I messed with the vents.All the seals ive replaced are orange.

 

now I got a rear left side seal gone. Leaking bad. What gives??? Also do both sides get the same seal or are they different?

 

well im up too 9 rear seals total 8 right and 1 left. The seal will go out every 2 rides. It doesnt weep it drips out bad. I dont know what to do,

 

Jack the back of your rzr up, put it in gear or park and move the rear wheells front and back and see how much play you have. When you do this, check and see if you see the axle moves up and down where it goes into your diff. If they do, then the slop in your diff (spool bearing) is probably causing your leak....The seal cant take that much flexing and will start to leak in a very short while... This is why my seals leak. I just keep the rear diff full and let it leak.

 

With that many seals being replaced, it would point the finger to something being wrong with the hub on the superatv axle. Maybe the diameter is slightly smaller where it interfaces with the seal? Do you have a set of calipers so you could measure what that dimension is?

 

well i thought about putting factory axles back in and trying that. I was thinking that maybe the inside of the diff is goin out. Also i noticed I could use some lower a arm bushings in the back.

 

Aight well today I installed yet another seal. I micd both axles and both are around 31mm i beleive i cant really remember. So I looked inside and felt the bearing it had no play whatsoever. So having said that unless the bearing is someway seized and I dont know it is then i guess i will just have to live with it. Local dealer quoted $115 for bearing.

 

:rofl3:

You make no sense to me (unless you are as dumb as "karn":rofl3:--sorry could not resist)......If you are replacinng seals and there is no relief in leaking diff fluid, then your problem rests within the wear of your diff gears and/or spool bearings...........I promise!