Leaking Front Differential

I was just out in the garage and noticed a small puddle of oil under the rzr, so I got to looking and it's coming from the passenger side of the front differential around where the axle comes out. Could it be just a seal or something more serious? Didn't look like it was cracked but I couldn't tell without tearing into it closer. Both the axles had alot of play in them too when I grab them and wiggled them. Is this normal? I don't think it is but it is a popo.

I just had the same issue on my 09....i replaced the seal and all was good til i was putting it back together....my axles both had a lot of slop....BOY i am glad i still had some warranty left....1380 bucks all new front diff.

Best bet is to pull the diff n tear it down. I did mine to replace the plastic sprague carrier with a billet one n discovered that the carrier had a crack which left in checked will destroy the entire diff. I replace seals about once a year, it is simple to do. Now that being said the crack didn't cause the leak but a bad bearing can compromise the seal n cause a leak.

Would the seal be covered under warranty? I can do it but if it's still covered I might let them do it.

Cale wrote:

Would the seal be covered under warranty? I can do it but if it's still covered I might let them do it.

You would think so but I would call and ask your dealer I'm sure they have seen this before

Ok thanks guys

Mine was covered but my dealer also warrantys cv boots also by replacing the whole axle....

I'll give my dealer a call tomorrow and see what he says. Guess I had better get my butt in gear and get it cleaned up from last weeks ride.

I do happen to have a gasket if you get in a bind i could drop in the mail...

Never seen a front diff tore down yet and I don't know how they are made, but I think they are all junk. I've grabbed the front axles and could move them around a little on alot of quads. The 450 did it just a little, the rzr I had did it alot at 400 miles when I did my 1st bushing job. I don't know if it's ok for them to do that or not, but it doesn't make sense to me. I know my way around this stuff on a truck like you wouldn't believe, but I have never messed with one of these.

If it were mine, I would spit the housing and look for damaged parts and if everything looked ok do the seals and call it done.

Cale wrote:

I was just out in the garage and noticed a small puddle of oil under the rzr, so I got to looking and it's coming from the passenger side of the front differential around where the axle comes out. Could it be just a seal or something more serious? Didn't look like it was cracked but I couldn't tell without tearing into it closer. Both the axles had alot of play in them too when I grab them and wiggled them. Is this normal? I don't think it is but it is a popo.

How many miles on your rzr and how often to you change the front diff fluid...I have seals for 8.00 each....I have sealed bearings for 20.00ea(you need 3)The front diff holds 6.75oz and should be changed every 500 miles...most of the play is in the axles, not the diff.. and believe it or not is normal...give me a hollar if you have anymore questions...704-929-0226

bubba53 wrote:

Cale wrote:

I was just out in the garage and noticed a small puddle of oil under the rzr, so I got to looking and it's coming from the passenger side of the front differential around where the axle comes out. Could it be just a seal or something more serious? Didn't look like it was cracked but I couldn't tell without tearing into it closer. Both the axles had alot of play in them too when I grab them and wiggled them. Is this normal? I don't think it is but it is a popo.

How many miles on your rzr and how often to you change the front diff fluid...I have seals for 8.00 each....I have sealed bearings for 20.00ea(you need 3)The front diff holds 6.75oz and should be changed every 500 miles...most of the play is in the axles, not the diff.. and believe it or not is normal...give me a hollar if you have anymore questions...704-929-0226

It's got almost 1400 on it, I've changed it twice so it's due for another. Thanks Bubba I might be giving you a call depending on what the dealer says. Hump I'm in the same boat never messed with one of these before so I'm kind of in the dark.

If you tear it down all the way, just put all the shims exactly where they came from if it has any. Torque all bolts to factory specs and don't use loctite or anything like that on any internal bolts.

I agree with Bubba on the play being in the axles. If it was the diff bearings flopping around like that there would be huge amounts of bad noise and vibrations that would make you afraid to drive it at 10mph, and there would most likely be a hole in the housing with gears hanging out. But, check the bearings anyway while it's tore down.

Got it cleaned up yesterday and called the dealer and they said it should be covered. It looks like I'm going to be off today so I'm going to try and take it up there if I have time after my daughters ball game. I've been dealing with the head of the service department there for years so he should take care of me.

Cale wrote:

Got it cleaned up yesterday and called the dealer and they said it should be covered. It looks like I'm going to be off today so I'm going to try and take it up there if I have time after my daughters ball game. I've been dealing with the head of the service department there for years so he should take care of me.

Thats great news.....good luck

Well i got mine back tuesday...it needed new pinion gear and bearings and what not...the warranty company decided it was cheaper to give me whole brand new diff then it was to rebuild mine...i even got two new axles out of the deal... they said the old axles that been in there wobbling around could be wore and cause wear in the new diff.

I've got spacers on my wheels, should I take them off before I take it? I still have the factory tires and wheels.

It wouldnt hurt to take them off to be safe...some dealers are cool some aint...its a decent couple dollars on the line...i would take the couple minutes to take them off.

Cale wrote:

I've got spacers on my wheels, should I take them off befote I take it?I still have the factory tires and wheels.

Cale...if they try to you I got your back...I've rebuilt two front diffs and if it only needs seals and bearings I can do it very reasonable....