Polaris RZR Complete Front Differential Rebuild - DIY - In Depth + Step By Step How To - RZR Turbo
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- เผยแพร่เมื่อ 1 ธ.ค. 2019
- Step by step process of how to rebuild the front differential in your Polaris RZR. In depth description of every step. Follow along, it's easy!! Visit our Shopify store and get your AdrenalineJunkieProd Swag Today!! teamajp.myshopify.com/ Check out our other videos and stay tuned for all the awesome content coming your way in the future!
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You guys asked for it and here it is. A bunch of people wanted me to film a video on how to rebuild a front differential from start to finish so I've finally gotten around to doing it. I hope you guys find this video informative. I tried to cover as much of the process as I could in detail. I made sure not to skip anything and did my best to discuss what I was doing as I did it. It is a long video but if you watch this start to finish you should be able to rebuild the front differential in your Polaris RZR with no issues. This is not difficult, it sounds much scarier than it is. If you have any questions or think I left something out then leave a comment below. If you enjoyed the video then also leave me a comment and let me know what else you would like to see. All the feedback I get from you guys helps me improve future videos. Thanks for watching and thanks for the support everyone! If you found the video helpful please share the video with your friends on social media and subscribe to the channel!
Super informative video i watched it before i rebuilt the diff in my 900S which is almost identical to the turbo diff. Was a huge help in putting it back together because i took it apart over a week ago and then the parts showed up so I put it together today.
Keep it up!!
How did you get the bearing off of the hub with the plastic washer? I’m rebuilding mine now
Oppoooppoopppoo ooooph pooooooooopppooppoo POP pooh-pooh l
Did it engage on the table with a battery or did you have to drive it around in 4x4 before it started engageing?
The gear you are calling (the main gear) is called a ring gear and it drives the cv shafts the one you called (the output gear) is actually called the pinion gear and that is your input from the transmission/transfer case. Not trolling ya buddy just figured I'd give ya the proper terms and uses
Great video!!
Thanks for taking the time to make it. The inside bearing cage fell apart in a million pieces when I removed the pinion seal, now I am just waiting for my 💣 proof kit from Sandcraft to show up so I can reassemble the front diff. Will definitely be using your video along the way as I put it all back together 👍
Hey Rick, glad you found the video informative! I had excellent luck with my Sandcrafft RCR internals. Good luck on your rebuild.
Thank you. This is my first rzr and I bought it used. I'm more of a wood guy, not mechanical at all. I had no problem following your video and getting the front diff rebuilt. Keep surfing the dirt everyone!
Hey man! Stoked this video helped you rebuild your diff. My goal was to make it easy to follow for anyone so it sounds like I achieved that. It’s a very simple diff design and as you can all see from the video there is not much to it. Thanks for the positive feedback!!
Awesome vid dude! Glad to see you do these kinds of videos where you show every detail of the process. For instance, most people would've just cut off the part where the input bearing didn't come off that easily. Appreciate the effort and precision you put into making these videos and maintaining your machines!
Glad you enjoy all the details Sami. I find a lot of installation videos just touch on the basic steps but don't actually show how to complete them or what to do when you run into common issues. For more experienced mechanics its not a huge issue figuring things out but for the novice mechanic it can really lead to a lot of problems or collateral issues.
As much as I love the ride vids I also really enjoy these. They help me with the confidence to know what to expect when maintaining my machine. Thanks for all the great content
Happy to hear you enjoy the variety and that you find the shop videos helpful. Appreciate the feedback. Lots more in the works!
Thanks for the video. I had the pin break on my XP1000 and take out the armature plate, so I have these exact parts waiting to install when I get back home next week. This video helps a lot!
Really interesting, I have bought a Polaris Ranger 900d ex farm. Bottom run to distraction. Rebuilt back end then got to the front. Plenty work but then noted a diff bearing was shot. Lot more confident now I have seen the video. Love the fact you show it as it happens warts and all. Thank you.
Really liked this video, hope to see more repair, component rebuild / upgrade videos in the future
Glad you enjoyed the video Michael. I'm working on an in depth exhaust removal and replacement video now. Removing the exhaust from a RZR turbo including the downpipe, as well as, extracting the broken studs out of the turbo which is a common problem when you try to remove the downpipe. Then a complete step by step install of the HMF turbo back exhaust system. I find a lot of installation videos just touch on the steps but don't actually show how to complete them or what to do when you run into common issues.
Most in-depth video I’ve saw on rebuilding a diff. Will def be using your video when i do mine. Thanks for taking the time to show us how to do it, def saves some money and looks somewhat easy.
Glad you enjoyed the video. It is not super complicated by any means. Follow the video step by step and you won't have any issues with yours.
Great video. I impressed you pointed out the mistake during assembly. Everyone makes them. I’ve used the slightly heavier oil, full synthetic. The synthetic oils do not turn into molasses in the cold however, he equipment I work on isn’t exposed to the Canadian winter cold. Thanks for taking us along.
Making mistakes is part of the process, learning from them so we don't repeat them is the goal. Glad you thought the video was well done. Ya, I guess synthetic oils don't thicken up as bad as the cheaper dino based ones. I'm going to have to do some more research on what my best options are.
Great video. Love the step by step. Started watching your trail videos a week ago. I have been wanting to get a RZR for a while. After watching your trail videos, I am definitely getting one. You should make more of the step by step videos. Your voice is very relaxed and easy going. Makes you very easy to listen to.
Thanks a ton for the positive feedback! I appreciate it. Happy to hear you enjoy all the videos, I'm glad you found our little piece of TH-cam! Also glad I could be a negative influence on you, LOL!! The SXS/UTV world is a ton of fun and it is loaded with a lot of amazing people! I can't imagine life without a SXS at this point. Let me know what machine you end up getting!!
Thanks so much for this helpful video! Just finished rebuilding the diff on my 2018 xp 1000. Instructions were spot on!!!
Hey John, really pleased to hear the video helped you out. Ride safe!!
Definitely super helpful, I'm changing out my 570 sportsman front diff,this is basically the same thing,just not as beefy! Thanks for the informative video,I couldnt find another like it....cheers mate!🍻
Neither could I which is why I wanted to make this video for quite a while! Glad you found it helpful.
My dad who was a mechanic at a paper mill always told me to put the bearings in a refrigerator or a cooler so as to shrink the bearings a touch so they'd go in a little bit easier. Which I've done and it works great. I'm glad you did this video I've got rebuild my rear diff on my Commander which I am sure is going to be close to the same as a Polaris
Hey Stacy. I usually put my wheel bearings and other bearings in the freezer for a few hours before I press them in too. Been using that little trick for years. On this application I didn't think I'd need it.
AdrenalineJunkieProd I understand been there also at times. Tell me if you know is the front diff and rear about the same other than the spider gears for locking it in and out
Thanks for the step by step I'll be doing mine real soon. FYI this may help for the liquid tape, try some pipe dope around the thread of the can. We do this on our glue and primer cans and works well and much easier to open. Thanks again for the video
Excellent vid AJP! Loved it and you do things right cant wait to see more but only upgrades repairs are heart wrenching😞, BUT ALL PART OF THE GAME LOL, ty guys and....KEEP EM COMING!!! 🤙
great video now when I need to do mine I won't be as intimidated, don't worry about mistakes as long as they are corrected some times you learn more from a mistake, you and everyone that watches this video will pay more attention to the installation of the cage for future rebuilds
Glad you found the video informative. Ya, it's not that bad of a job once you dig into it. I agree, mistakes are just opportunities to learn and improve. The goal is to learn from them and not repeat them. No matter how many times you do something you are always learning and developing new skills.
Thanks for the excellent video. Your videos provide material that a person enjoys watching and learning from. I ride for enjoyment of the scenery around me. I'm glad your videos are not like the ones that build UTvs into drag vehicles, using car motors to run in a straight line.
LOL... super stoked you enjoy the content. I too like to think I use these machines like they were intended to be used. I appreciate the mechanics that goes into those unique builds you mentioned but it's not why I ride a SXS. To each his own though. Those other channels seem to get some insane view numbers so I guess a lot of people do enjoy them. That's the beauty of the internet though, anyone can post and watch what they like. Thanks for leaving a comment!
Thank you so much for this video. It helped me rebuild my differential in record time!
Glad it helped! Stoked it all went well for you. It's a very simple design! Worst part is taking the diff out and putting it back in the machine.
This video helped me out big time. I had the same problem with bearing being stuck. Did the same thing you did , worked out great 👍 now just waiting for my bulletproof kit to show up .
Happy the video helped you out with your rebuild!!!
Thanks for doing this and posting the video. I really enjoy your videos as someone that new to the hobby. I like doing my own work and this is something I've been curious about.
Hey Joseph. I'm glad you found the video informative. These machines are quite straight forward to work on and the front diff as you see isn't too complex of a setup. My goal was to show people that if you just take your time it's not that scary of a job. Getting the diff in and out is the part I hate the most.
Amazing job man. I liked how you showed your failure points too. Im sure it will help a bunch of people!
Thanks for the feedback, I'm glad you found the video informative. I specifically left the failure points in there for that reason. Realistically these are very basic components so if you watch this video there is no reason you can't rebuild your diff too! Glad the video came together as well as it did.
thanks man i feel confident that i can rebuild my 2017 RZR turbo front diff.
Ya, you'll be fine! It's easy man.
Thank you for making this video. You helped me put the diff back together. Awesome video
Video was a lifesaver!!! Thank you
Thank-you for the video, it just helped me with everything! There was one problem I ran into that wasn't covered however. I followed step by step your video and once I get the case bolted back together my output shaft of the differential wouldn't spin. It turned out to be a case bushing needed hit down about 1/100" to sit flush in the diff housing. The bushing is red in color, and it's the lip that the little plastic ring sits on before installing the ring gear, and I completely overlooked it. Just a heads up to anybody else, thanks again!
Great content. Liked seeing the possibility of problems and knowing what kind of stuff to look for. Enjoyed watching.
Thanks Ride Command 18, I'm glad you found the video informative. I just wanted to demystify whats actually hiding in that front diff. Not much... It's a really simple and solid design. Polaris has a wicked 4WD system and this simple front diff is part of why it works so well.
AdrenalineJunkieProd are the NA diffs close to the same design? I know yours is turbo.
I have watched your videos a lot ! There bad to the bone ! And I ran in to this problem and thanks for showing me how to fix mine, wish I could go trail riding with you guys 🤘🤘🤘
Stoked you enjoy the videos Erick and I'm glad this one helped you out!!! Where are you from? Where do you ride?
Thanks for the video. Very informative. Have a 2010 rzr 800. The shaft bearings are a little different but definitely get the idea. Thanks
You explain things very well, love the video and your channel!
Thanks so much! Stoked you enjoy all the content and I'm happy you found the video informative.
I got about 11,000 MI on my ranger right now and I got to go through that front diff now do it myself as well and this is a really good video for me to watch
Awesome job. Was thinking about doing mine. Now I will!
Glad you found the video helpful. It’s not a hard job, you’ll manage just fine.
This is an excellent video one of the better How To's I have watched. - Thanks - BTW I have a 2019 Commander 1000XT
Thanks, I'm glad you appreciate my OCD approach, lol. I've never had a Can-Am front diff apart before, I wouldn't mind exploring one in the future. See what makes that Visco-Lok work.... or not work, LOL....
Great video guys.. Hopefully I wont have to rebuild my diff but if I do, this is the video for instructions. Thanks for making it! Next time you come to TN, we the Mudnight Riders, say COME RIDE WITH US! We ride mostly Royal Blue, Pickett State Forest and Windrock. Sometimes Brimstone and Tackett Creek.. Thanks again and lets ROCK and ROLL!
Thanks Thomas, Can't wait to get back down to TN!! Would love to ride with your crew.
Excellent video lov the how 2s keep up the great vids
Thanks Rad49. Glad you enjoy the How To videos. I know this video might not appeal to as many people as a ride video but you can't ride without a functional machine. I'm hoping that the people who it really appeals to find it helpful in rebuilding their differential.
Great job. Great in depth display and step by step. Thanks.
Happy to hear you found the video helpful and informative!!
Way to show it like it really is I'm going to tackle mine now.
Necessity is the mother of invention and I think you got it
I had this exact thing happen on mine just last week. It took me forever to get it out.
Great video very informative very methodical again great video help me out immensely!!
Really happy to hear you found the video helpful!! If you own a RZR a front diff rebuild isn’t a matter of if just when, lol!
Thank you for the great video!!
Craig Greve you welcome. Glad you found it helpful.
Thanks for the instructions,
That is one very interesting video you guys did a good job
Awesome video. Very helpful.
Thanks. I’m glad you found it helpful.
Great video....I use rotella T6 in my machine in the front ,motor,and trans
Very well done and extremely thorough
Thanks! Glad you found the video informative.
Great video, very informative.
Glad you found the video informative Shaun!
A god tip for bearings that fit on the outside race is to pop it in the freezer unless your in a big hurry. I have always done ball joints that way on Pickups. Or an oil bath on a hot plate for fitting the inside race to give you 4 or 5 extra thou. But so far looks like a good build. So far im at pinion seat
The freezer trick is awesome, I use that method a lot on many projects.
Great video, thanks from Alabama
Glad you enjoyed it Danny.
Great video❤
Thanks. Glad you like it.
Awesome video thanks
That snap ring wear groove gets everyone lol. A tiny bit of heat on the housing helps it walk right out. The factory Oem Peer bearings are junk. I'm running Shell Spirax TXM fluid in the front diff and transmission. I believe it's about a 30w oil. I'm in Alberta.
Helped alot. I did the new bombproof diff tho. Very similar. Slight bearing difference. Thanks for the awesome video! You ever Wana ride in maine or come to Maine DM me!
It's nice to have hair ties alot of use for them I used one of my hair ties to hold up the timing chain
Amen to that brother! lol. They are on the list with, duct tape, zip ties and WD-40!
Awesome video, great content and very personable feel like we got to know the man behind the camera… keep it up brother
Awesome video 👍
Thanks Chris, glad you enjoyed it!
You are the best. Thank u
Your welcome. Glad you found the video helpful.
Just order the the diy kit from sandcraft, the armature plate packaging has a label saying “run your machine with Four-Wheel drive engaged for 50 miles”
Did you do this immediately after the rebuild or did you run it in two wheel drive for a while first?
Also, would you suggest 4 high or 4 low for this “break in” period.
Good info,thanks
Definitely work on my machine and others.
Awesome video
what you have here is a flanged edge from the snap ring , the torque did it . a flat edge file on an angle will cut it off be very carefull not to take too much, slow and eazy is the answer.
Hey man great Video. I have a 2010 polaris sportsman 400 hd and the teeth are gone of my axel hub on one side. Where in the heck can i get replacement parts? I have looked all over, any help is appreciated.
You got balls using that press ... I've had my fair share of pressing bearings and have pucks and metal rods slip out from under but other then that I loved the vid man
Glad you liked the video. The press fits on this application were by no means super tight. I know what you mean though, I've pressed stuff before where you think everything is gonna explode and sometimes it goes flying across the shop! lol. All of the parts came apart really nicely this time... key phrase... this time, lol!
Looking forward to hearing your review after you get some miles on it. ( or km as we Canadians say. Lol ) My front diff is getting pretty noisy. Carrier bearing for driveshaft was replaced and that helped the noise but the diff itself is getting pretty loud. But only over 50km/hr.
Ya, it's common to only hear the noise above 50km/h at first. The stock carrier bearings are encased in rubber and have a TON of play and slop even when new. I run a billet carrier bearing from SuperATV. Makes a massive difference. I also run their Rhino Driveline chromoly prop shaft. The stock prop shaft are generally out of phase from the factory and make a lot of noise and vibration at high speeds.
Great video! Thanx!
Happy you found the video helpful!
2014 xp4 1000. The front 4-wheel drive stopped working, I took the 4x4 gear case out and took it apart...everything looks good. magnet tests at 25 ohms, if I energize the magnet on the bench the armature sticks. If I put it together on the bench and spin the pinion, then apply 12 volts to the magnet....the axles do not lock and start to spin. It seems like they should and that I still have a problem in the gear case. Should the axles lock and start to rotate on the bench if 12 volts are applied to the magnet?
I just did mine. I took it out and it feel super “tight” in the front diff when I put it in 4wd if that makes sense. I called and they said there is a break in period. Did yours have the same tight feeling when you first rode it after the upgrade? Just seems weird to me and I don’t want to mess it up. (I hope you still read comments) 🙏
Great video
Great video u should do more videos like this cause ur so in depth anyone could do this thanks alot good tip with hair band lol
Stoked you enjoyed the video. I tired to be as in depth as I could because I do believe its a pretty straight forward job as long as you understand what you are doing and follow the directions. This video should provide all the info anyone needs to do this job if they really want to.
What would you recommend I use to upgrade my 2015 Rzr 570?
Thanks for the video!
You're welcome! Glad you found it helpful.
Putting the casing in a warm area and the pinion shaft in the freezer helps when you want to put them together.
Also a little buffing with Emery cloth in the bore would help you out next time
That’s a great tip. I’ve been using the bearings in the freezer and housing in the sun for a long time when I do where hubs and other similar press fits. Sometimes putting the hubs or items in an oven is a great idea.
I just re did my 05 sportsman 800 rear diff and they gave me a total of 4 seals.. 2 for the axels and 2 other ones that were the same size .. one is a rubber black one the other was like a goldish color.. I think I messed up I put the gold one where the driveshaft goes couldn't find out where to put the other one? So where does the other one go ?
What is the tq spec for the case bolts? I also noticed you just tightened the bolts in a clockwise order. No sequence needed or is that sequence? Great video. I like to research parts/repairs before I break them lol
Very good video bro! Very informative.
Thanks Joe! Glad you found it informative man. That was the goal, lol!
@@AdrenalineJunkieProd BTW how many pound press is that u have?
@@JoeWilson4 Its just a standard 20 ton press from Harbor Freight or our Canadian equivalent, Princess Auto.
@@AdrenalineJunkieProd awesome thanks.
I have a couple questions, 1. What is the heavy clicking sound when the front tires grip on something is it the axles to hub or ring to pinion? 2. What us the most common failure point of all of the 4x4 drive system.
Good video buddy....
Good job !
I watched another video of front differential rebuild and the axle bearing with the white plastic washer was on the top side with the armature I’m in this process and mine was like yours in the video and how I took it apart bought it used don’t no if it rite or not
that was about as detailed as you can get. Good job.
Thanks! Glad you enjoyed the video!
I have watched numerous videos to see how to install the sprag rollers. Thanks
Your welcome Bill. Hope the video helped.
Thanks for the video! Very informative and helpful video.
Glad you found the video helpful and informative 56 Chevy. Thanks for the feedback!
What do you think this can be I have my from diff every thing looks good but as soon as I put bolts on top cover you can’t twist output shaft without having a set of pliers and a lot of torque Dosent spin easy but if you take cover off it’s spins easy ?
Thank you I don't own a Polaris yet I just wanted to see how it diffs are rebuilt on these toys
Your welcome. Glad you found the video informative. It is a very simple and reliable design.
Well done thanks
I just installed mine using your video as a guide (thank you, much appreciated!).
Did your diff make any noise and vibrations after the install? I’ve got feedback in the steering wheel and noise from the differential at full steering lock, worse when on throttle. I was told by Sandcraft it may be just the 12 tooth armature plate getting seated and worn in. Thoughts?
Hmmmm. Interesting. Is it bad? What kind of feedback? Mine felt fine and I've had mine apart again since. I had to replace the input bearing and I replaced all the seals. I inspected it all when I had it apart to do that and everything looked great aside from the bad bearing. Sandcraft was awesome to deal with, they warrantied the bearing. My diff felt good from the time I did this. I've been quite hard on it a few times and I had it ratchet and do the diff crunch a few times but when I took it apart everything inside looked great. I've been happy with this setup. If I am in 4WD on asphalt or concrete then the front wheels are a little hard to steer and I get a bit of feedback maybe but that's expected. In off-road conditions everything seems fine to me. Is your prop shaft in good shape? Is your hanger bearing in good shape? I have a SuperATV Rhino utility series chromoly prop shaft that is phased correctly and balanced. I also have a solid billet hanger bearing from SuperATV. Often a lot of driveline vibes up front are caused by the stock prop shafts and hanger bearings. Can you explain in more detail what you mean by "feedback" and what kind of noise?
I don't even own a Polaris.... I just like to see how stuff is put together. SKF bearings are very common in industrial gearboxes. Largest one I ever worked on had a 2ft diameter and cost $4000 dollars.
I can relate, I also enjoy random knowledge lol. The more we know the better, sure beats watching a reality TV show... haha. Ya, they make some massive bearings.
When you were pressing off the original axle cup bearing, one side had a plastic disk (white) behind the bearing. Did that crush/extrude when you removed the bearing? I am about to take mine apart, and I was trying to figure out how to fixture it in the press to get behind the bearing without crushing the plastic spacer
Sorry for the late reply. The plastic piece was not damaged during disassembly.
Great video 😎😀😎😀😎
Glad you enjoyed it
Great video, I should of done a video myself.Done about 8 of them
where did you order the bearings and seals and what are the part numbers?
Good job man
Thanks!!
awesome video brother yours was definately the best ive seen on youtube. a lot of videos are not very informative or careless. top notch. only thing i have not seen is the reviews of the sandcraft parts after people swap them out and use them as well as the driveline and carrier bearings. these machines are notorious for this and im about to do mine. had a bad vibration on acceleration and a lot of chatter. how did you like the product after?
I appreciate the feedback!! I'm super happy to hear you feel this is one of the better videos on this topic. I put a lot of time into trying to make this as step by step as I could. It's not really a hard job when you break it down. As for the Sandcraft parts, I'd say they are good. Also, Sandcraft does a good job standing behind their products so if you run into any issues they are reachable on email or the phone to assist. I had great results with this kit. As far as a stock diff goes its a top choice for toughening it up. I'm about to swap a fully built RS1 front diff into the RZR Turbo. I got Joe Coffman from CCM to build me a "Hill Killer" diff. I'll be doing an in depth video on that soon. I've heard great things about the Sandcraft hanger bearing setups. I've been running a SuperATV Rhino HD utility series prop shaft with SuperATV billey hanger bearing for quite a few seasons with excellent results and no failures. I like the setup.
could you zip tie the rollers as you expose them prior to pulling the whole sprague out?
Thank you for showing this rebuild. I have a question, does a 2019 1000 Non turbo still have the reverse chain or are they great driven?
I believe the non-turbo has a chain. Maybe someone else can chime in that knows for sure. Glad you found the video helpful!
I about passed out when you blew those drill filings all over the parts. Use some grease on the bit and take it way from the scattered parts to clean it off. I know you wash everything before install but why take a chance. Also as noted bearings in freezer helps. Wasn't keen about the hammer either. Everything else was to the letter. Good Job.
Ya, by no means was this perfect. You are not wrong about any of the stuff you pointed out. Needless to say the diff has worked flawlessly since I rebuilt it. Glad you enjoyed the video... minus the cringy bits, lol!
Sprague carrier elastics hahaha. Clever. Great video
Thanks, lol! Happy you enjoyed the video.
so does the sandcraft sprague cage fit into a 2012 polaris rzr 900xp? each website i look at them, they only go back to 2014
Hey Chaz, the best thing to do is to call them with a question that specific. They were great to deal with on the phone when I called to ask about recommendations and suggestions.
Thank you!
You're welcome! Glad it helped!