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What Broke in the Front Differential?

9K views 18 replies 8 participants last post by  AJsRZR  
#1 ·
Last night when i pulled the plug for the front differential this little piece of metal was stuck to the drain plug.

Is this the pin I have read about that will break, then 4wd will automatically engage at higher speeds? If so I have a ride this weekend, will it hurt anything to drive it like it is until I get a chance to fix it?
 

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#2 ·
BTW, i was reading on the type of oil to replace the front dif. and rear/transmission. it looks like the rear dif/tranny uses regular GL-5 gear oil.

I'm not close to a Polaris dealer, but I read it was basically hydrolic fluid from John Deere for the front differential. I was planning on replacing it with John Deere Hy-guard as we have 55 gallon drums of the stuff around here. This is what John Deere uses for their transmissions/hydrolic systems, is this ok and what people are running in them?
 
#4 ·
ok, thank you for the help. To be safe i will keep it in awd so it doesn't kick in and break something.

Now I just need to find time to pull it apart and put in a stronger pin, and find that link that had instructions for it. I believe they were just using roll pins, correct?

BTW, what is the deal with the plastic versus aluminum sprage? Are those prone to fail also on these? If I'm pulling it apart is there anything else I should look for to change?
 
#6 ·
I don't know the exact build date, but i knew the guy that bought it originally. He bought it before memorial day last year. Thus has to be a pretty early build date.

Only the early ones got the aluminum sprague? If i'm not mistaken that would be the better and stronger unit. I hope so, fix the pin and call it good. I might also have a new drive shaft made as when going down the road it does make a lot of racket.
 
#8 ·
i broke mi transmission going on reverse, didnt knew what was going on until i hit the gas again and the hole thing broke... i have 7 months with the rzr xp4 1000 and has only 80 miles on it.. i went to my dealer and told me they coudnt do anything about it because the warranty only covers 6 months but one guy ho works there told me to talk directly to polaris and that they might help me because its a malfunction that polaris knows about it..
the main problem is that the transmission its very expensive and might happend again, someone told me about the highlifer edition transmission but my dealer doesnt have a clue about that..
what do you all know about it, and do think i might get help from polaris..?
 
#12 ·
i broke mi transmission going on reverse, didnt knew what was going on until i hit the gas again and the hole thing broke... i have 7 months with the rzr xp4 1000 and has only 80 miles on it.. i went to my dealer and told me they coudnt do anything about it because the warranty only covers 6 months but one guy ho works there told me to talk directly to polaris and that they might help me because its a malfunction that polaris knows about it..
the main problem is that the transmission its very expensive and might happend again, someone told me about the highlifer edition transmission but my dealer doesnt have a clue about that..
what do you all know about it, and do think i might get help from polaris..? View attachment 131140
Unfortunate, but really has nothing to do with this thread ;-/
 
#11 ·
Yes that is the pin, but it is not a standard roll pin, it's a spiral pin. Similar to a roll pin but but has more "layers". If it's been broke for any time it's probably broke the carrier and messed up the reluctor ring. For the 14 year models with the aluminum carrier Siper ATV has a replacement carrier and reluctor ring for way cheaper than stock.
 
#13 ·
Looked up the date on my rzr and it was an early one. shows date of august 2013.

Is it the early models that have the aluminum carrier, then later 14's and 15's got the plastic carrier? seems like i see contradicting information in different threads. I guess i will find out shortly as i will be pulling it apart soon.
 
#14 ·
My understanding is this, all 2014 models have the billet aluminum sprague.

All 2015 models up until a build date of 8-5-14 have the plastic sprague. After that they switched back to aluminum.


I don't know for sure what the Highlifter models have though.