The way they are shaped they look like the pinion teeth that mesh with the snorkel gear. All the other gears in the trans are helical and those teeth don’t look like helical gear teeth. Hard to tell from the pic tho.

 

Oddly enough that’s my thoughts as well. I plan to get into it next week and go from there. Gonna do the sand craft bearings while I’m in there. I’ll take some pics and let you guys know how it’s going. I have two buddies that have each done theirs so they’re gonna come help me when I get after it.

 

Just got into the transmission. Found my issue. Gear on pinion shaft came apart. Now to get some new parts and upgrade a few while I’m in there.

 

Parts ordered. Got some from SuperATV and Hardline UTV. Now to clean stuff up and get it ready to go back in.

 

Any ideas as to why it failed? Make sure the entire trans is setup properly because it would suck to put it all back together and have it fail again!

 

Agreed. Not sure why it failed. Blows my mind. It’s got 1,100 miles on it and a majority of those miles are from my wife who isn’t hard on stuff. Strange part is it ran fine. Had I not changed the fluid I would of sent it this season. Probably done more damage. Taking the cases to my dads shop on Monday to put them in the parts washer. Once I get the pets I’m gonna assemble at his shop with a couple of my buddies who have done 2 transmissions each. Taking my time and torquing everything to spec.

 

I ordered Sandcraft bearings just to be safe. Factory ones all felt fine but I’ve heard bad stories and while I’m in there I wanna do it right. Replacing the seals too. I had some seepage on the factory ones.

 

Looks like you’ve got it covered! Should be better than new when you’re done.

 

Get a heavy duty pinion retainer plate as well. I personally like Rock Ready but multiple places make them if you do a Google search.

 

Does anyone have a PDF service manual or at least the section on the transmission I could see? I've done a search but I didn't find any results. I want to see how its supposed to go back together per the manual. Thanks,

 

Not sure which model you have but try this - it should at least be similar

http://www.cincyoffroad.com/Manuals/2014-2015 RZR XP, XP4 1000 Service-Manual.pdf

 

See if this works

Microsoft OneDrive

onedrive.live.com

Edited: Can tell from the trans adapter you have an XP, link I posted is for XPT.

 

Thanks. Sorry. It’s a 2019 xp 4 1000. That ones for the turbo. Is the transmission the same?

 

They are similar but there are a few differences. I have an XP1000 paper service manual, if no one links a PDF then I can post some pictures out of it.

Is there anything specific you’re after?

 

The snorkel gear lash process and that cover on the outside with the 4 gears and spring. That part fell apart when I took the cover off so a little sketch on how that goes back together.

 

There’s a whole series of videos from these guys that are helpful for this.

 

I think I got the backlash set. It turns smoothly but if I grab the shaft and turn left and right I get a small click? Is that correct? I watched the above video and his seems to click the same way when he did it. I’m assuming that’s correct? Just want to be sure before I continue putting things together.

 

Is the clicking just bearing noise you’re hearing? Should be approx .005-.007 backlash, not much. If it turns smooth with no binding then you’re good to go.

I forgot to post any pics from the manual, were you able to find the XP manual online? If not I can take some pics of that section.

 

Yes. The manual you posted worked. I printed off the pages I needed and have been using them.
It turns smoothly with no binding. I have the “click” similar to the video at 22 min 12 seconds.

 

Normal. The biggest thing is no binding and not having excessive backlash.

 

I got the new Sandcraft bearings pressed on. That was a daunting task hearing the metal creek while pressing them on. Had a couple buddies help who have rebuilt their transmissions before so they made it a quicker process and had some good tips and tricks. Took about 2 hours and a couple beer breaks to get em pressed on. I assembled everything yesterday and finished pressing in the new seals today. Hindsight the seal that goes on the secondary shaft should be installed prior to installing the shaft and gears. This took me forever to get in. Finally made a press out of some 2x2 square tube I had sitting in the garage.
I “bench tested” the trans and have all gears and park. I have Tuesday off so I’ll install that day and give her a test drive. Gonna let the gasket maker cure for a few days before I fill with oil after the install. I used the green tube of permtex “gear oil” specific gasket maker.
I’ll update everyone on how it runs on Tuesday.

 

Got every being back together and happy to report it all seems like it’s working well. Getting the transmission just physically back into the rzr required some Tetris style moves. Got it in and took my time getting things right. Hunterworks has a good video of the clutch alignment. Got that done and torqued in the correct sequence and correct specs. Alignment bar slid right off. Inspected primary and secondary. Blew them out with compressed air and cleaned the surfaces with brakleen. Got those installed and belt installed. Cleaned axle splines and used anti seize on them to be sure an axle replacement on the trail is easy. Greased all 4 wheel hub bearings and got the hubs and brakes one. Took it for a spin and sounded good. On a side note I filled the trans on the bench and once it was in line with the fill plug I ripped it forward and added a bit more fluid. Decided to do the overfill method I have seen mentioned by others on this forum.
I want to thank everyone who has commented on this thread and helped me out though pm as well. I would consider myself mechanically inclined but by no means an expert. So I appreciate all the help. I’ve definitely learned some things. If anyone has to tackle this in the future and needs anything reach out. I also have some lessons learned I would be glad to share.

 

Got a quick question while some of you are talking transmissions. RZR Turbo S with about 800 miles. This is on the transmission drain plug. Thoughts

 

Sorry but that’s a chunk of steel, prolly off a gear. Good catch, running it would likely do some more damage. The metal ”goo” is normal.

 

I would err on the used of caution and take it apart. Who knows what that is but it’s big enough to be of concern. From start to apart on the work bench was about 3 1/2 hours. It seems overwhelming at first but it’s not too bad. If anything it’s your chance to upgrade the bearings.

 

Just stumbled across this thread. I've found a tooth on my drain plug too. I'm not looking forward to pulling the trans lol.

Does it come out from driver side or passenger, and will I need a lift or is it manageable?

 

I took mine out the drivers side. It’s not super heavy, but it is awkward. And it’s definitely easier coming out than going in, having to align everything back up again.

 

When I did mine, I pulled it out the driver's side. It's manageable to just man handle it. I'm not sure a lift would be able to grab it unless you take the bed plastics off and lift it out from above. It's pretty tight to get it out from the side, but it saves a bunch of time not having to remove the bed plastics and all that entails.

 

Alright, I guess I just need to commit to it then.

One thing that's got me curious is can the gear reduction on a High Lifter be removed? Anyone got a schematic of the difference between the regular XP vs the HL? They both look identical to me when I look them up. Thinking of removing mine. Truth is I didn't even know I had a gear reduction until recently, and I do more fast trail riding than mud so I suppose I don't really need it.