Welcome to my world I have been living for several months. BEFORE you take the springs off the new OEM sprague, install it and see if it works. I am going to finally do this to mine. This will tell you if it is the sprague or not... Here is some good reading for you

http://www.rzrforums.net/general-rzr-discussion/90931-another-5-billionth-front-diff-question.html

 

I have watched a video on youtube where the guy hooks the 12v straight to the plug on the diff and it turns when he turns the pinion by hand. I tried this last night and mine would not do that, I have even plugged the mother f***** in with the diff apart and it has good resistence when i flip the switch and try to turn it by hand. I can make it engage on the bench if i spin the pinion and hold the armature plate by hand until it locks in though

 

last night i put the differential in with out putting the axles back in and hooked everything up and it wouldnt engage i guess it should work without the axles in it, maybe it needs the resistance from the axles and hubs though, im just tired of dealing with it.

 

I just had an idea, maybe i should take the new sprague carrier and grind it up like the plastic one was and throw it in there, at least i would have awd going forward

 

I had to replace the cover. It looked fine but must have been worn too much.
Try a new cover.

 

Im going to try the factory sprague carrier i have ordered first if that doesnt work i guess i will try the cover that will be the only thing left.

 

If the cover is in proper ohm spec, its not the cover. Most likely 1 of 2 issues (same as me) The springs are not allowing the bearings to compress against the hubs because they arent properly bent OR because the sprague isnt grooved deepenough to allow the bearings to compress the proper distance. If it works when you put the stock sprague in, then put the new springs in the aluminum one. If it doesnt work then, you know its the sprague.

 

we'll find out whats going on im on my way to pick the sprague carrier up now

 

Any luck?

 

with that brand you bought, it requires you to bend each spring a tad,*that info should be in the instructions, mine was) pinch them closed a little bit, trust me, i had the same problem. bench test it before installing with 12v. problem solved

 

super atv brand , picked up oem sprague carrier just so happens it was cracked in the packaged so i swapped the springs over to super atv piece still the same no awd only thing i know to do is try the new side cover and an oem armature plate.

 

you should be able to hear the armature, tap, when 12v supplied on the bench

 

you can hook power to the plate and let the armature plate go against to see if its working as well..

 

Does anyone know what would be the best differential to use if i just replace the whole assembly, with out any modifications , do the newer models come with the aluminum sprague from the factory

 

If you really wanna go that route, box yours up and send it to these guys.

Jeff Robbins
"JJ and A Racing Products Inc."
shop 503-826-9402
cell / text 503-307-4643
www.jjandaracing.com

Call and talk to Jeff....

 

X2 i installed there sprague that came with springs and rollers, and also got there bearing kit too, while i had diff apart.

 

what about the front diff out of a 2013 rzr 800, it looks to be a little more heavy duty, wonder if the driveshaft is the same?

 

i ordered a holz racing sprague carrier and put it in and it works excellent, measured the space between the rollers on the super atv unit and it appears the slots are not machine out quite enough for the springs to move and let the rollers move properly the holz racing iunit is super smooth , thank you for all of the help along the way guys!!!!!

 

got it back together and the awd will not disengage up on the jack stands, when i bench tested the diff on the work bench it would disengage when i unhooked the power to it. Do the wheels need to be on the ground for it to disengage properly you think? Armature plate is also new. The front seems to disengage with the key switch off

 

the front differential would not disengage because the bronze bushing in between the to hubs was worn down. Im guessing because the carrier was broken for so long, when i installed the axles it would bind up and not disengage.

 

Just because the coil ohms out doesn't mean the cover is necessarily good.i had one that the coil had shifted in the cover and the distance to the armature was off enough that it wouldn't hold it.

 

does anyone know what wren did to fix his 4x4 working