trouble with the front diff

i was riding yesterday and the front wheels all of a sudden felt like the brakes was pushed in about half peddle.i could back up and it will free it up and i can drive 10ft sometimes and others i could go miles.
it done this at brimstone once and after i backed up it was fine for the rest of the day.

i checked the fluid today and it was a little low. so i changed it and took it for a drive and in about 50 ft it done it again so i turn around and go back and jack it up and turn the front wheel and i can hear some clicking that sounds like its in the front diff. the wheel is kind of hard to turn forward but easy in reverse.


i have the rzr took apart and going to pull the diff tomorrow. i suspect the plastic cage inside the diff is broke.


has anyone had anything like this happen to there rzr???

I would say all that clicking has busted the plastic carrier.

Anyone that has replaced the plastic carriage, is the replacemant plastic as well?

the polaris part is plastic. but they say a johndeere part works and its medal. and superatv makes an aluminum one.


http://www.superatv.com/POLARIS-RZR-SPRAGUE-CARRIER-FRONT-ROLLER-CAGE-550-P465C245.aspx

i got the diff out and took apart! the plastic cage is broke. it has several pieces chipped off of it and there is also some muddy water in it. looks like the breather hose is stopped up with mud.
i guess its time to order parts and get it back together and .

also going to put new wheel bearings and ball joints in.

Looks like you got plenty of work to do Bush

it sucks that this had to happen when im on my vacation!! but at least i have time to work on it.

i guess im going to get the cage/carrier from superatv.com . so now i got to find a diff seal,bearings and ball joints.

I think Stealth will be doing this soon. I heard is clicking pretty good too.

Bush.... check out cheapcycleparts.com...... They are the cheapest that I have got parts from.....

GETERDUN wrote:

I think Stealth will be doing this soon. I heard is clicking pretty good too.

Bush.... check out cheapcycleparts.com...... They are the cheapest that I have got parts from.....

i think stealth done took his apart and checked.


that is where i buy most of my parts from.

bush, hold up on putting a plastic one back in, i found the metal ones forv169.00 and they are bullit proof,


ok here is one, there is another company that has a nice one but theres is 259.00 on ebay.

Just a FYI, i noticed my breather tube for the front diff was just below the storage box in the front and could easily get water in it, i drilled a hole in the firewall and ran it inside way up high under the dash where it never gets wet.





http://cgi.ebay.com/ebaymotors/550-RZR-SPRAGUE-CARRIER-FRONT-ROLLER-CAGE-ARC-P-RZR_W0QQcmdZViewItemQQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem518bde39caQQitemZ350238947786QQptZMotorsQ5fATVQ5fPartsQ5fAccessories

I just rebuilt my front diff. also a couple of hundred miles ago.Except i found that there were 2 rollerbearings from within the cage that were never there to begin with cause there was not 1 single particle of any metal in my diff.It was clean as a whistle.I went back with the original plastic one only because it was immeadiately available that day so i could get it back together and ride.Havent had any problems yet.Just make sure when you go back together with it that you pay close attention to the adjustment of the armature plate to the coil.If you look it up in the manual on the adjustment procedure you will see what i mean ,cause if it aint right it still wont work.It is very simple to do after it is back together but before you actually reinstall the diff.in the machine.I went ahead and replaced my armature plate also just because it looked a little warped,and since i was going that far i replaced my coil also.Even if i didnt need it,at least i now have a spare.OH!! and most importantly...make sure you put the correct fluid back in the front also.My local dealer made that mistake on mine and that too also rendered my 4wd useless.Tha is why i do all my own work on it now.

i have got all the parts ordered but the diff seals!!! i can not find them anywhere. i have looked everywhere ans called lots of places and no luck. i found a part # on rzrforums.net that someone posted but its 50$ bucks for a seal and i just dont know its it the right part.

has anyone ever replaced the seals in the front diff???

Bush did you try NC Powersports ?

try babbitsonline they sell all oem parts, just look it up in there micrfish and it will give the pictures and part numbers and cost. they sell at a discount and send fairly fast.

tried both. they say they cant get them.


says you have to buy the whole cover.

babbitts shows a seal kit that has 3 seals, 45.00, looks to be all the ones needed.

http://www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

i ether screwed up on ordering the seals or i was sent the wrong ones.

That's a :Biatch:

it sucks.. i think the ones i got are for the rear!

Bush...you might as well keep them from the looks of all that in the front
diff the rear is probably the same

i plan on keeping them. i have read that a lot of people have had trouble with the rear seals also.

i have had the rzr back together for a few days and the new aluminum cage from superatv is working great. the install was easy and took about hour to hour 1/2 to reinstall the diff,axles,a-arms,wheels and ready to ride.
the diff seals held me up for an extra week. i ordered the seals for the rear instead of the front so i had to reorder.
i also put new wheel bearings and ball joints in.