Polaris Ranger Rear Differential Rebuild

Replacing bearings and seals in my 2009 Polaris Ranger XP Crew 700 rear differential.
Thanks to Bensound for the royalty free soundtrack!

[@canisemccomb3710]

After soaking all parts in degreaser we saw what you were talking about the pinion nut being swaged in the keyway. Used air grinder and drill bits to break down the swaged area and heated up the nut with a torch and used a deep well socket on an air impact gun and the nut finally came off! Again thank you for your all your advice! Greatly appreciated!!

[@barntech2291]

Glad it worked for you!

[@canisemccomb3710]

OK, we'll investigate more and try your other tip. Maybe even heat the nut up with a torch may help. Thank you for your replies you are a credit to us novice would be DIY'ers!! Thank you, C. McComb

[@damxgopak457]

Just a tip put the new bearing races in the freezer for a few hours before pressing them in they go in much easier with less stress on the machined surfaces of the casting.

[@barntech2291]

Freezing the bearing helps, heating the case helps, but if you have a hydraulic press that takes the cake :-)

[@piolin3603]

NICE,BRO.

[@user-cl8oh6ix7l]

My rear diff blew a hole right through the casing. I found a replacement for fairly reasonable price. Able to highlevel provide the disassembly/reassmbly steps? Thanks in advance

[@barntech2291]

It has been a while since I did it, but I think I showed the process in my video. A few things to keep in mind: 1) you will need a really deep socket to remove the pinion nut. 2) the hardest part will be removing the old bearings from the shafts, and 3) the new pinion nut must be sweged to prevent it from backing off later.

[@jeffreycormier3864]

I didn't notice any shims used...why not? Not needed? They came with my kit and were on the factory setup.

[@barntech2291]

I am pretty sure I put the factory shims back in. To do it right you should measure and put new shims but I did not have new shims.

[@fegolem]

I'm helping a friend work on a 2013 Ranger Crew 800. How much slack or slop is acceptable in the rear diff? Looking in through the oil fill hole in the back, it uses a chain. The slop seems excessive but I don't know what it its supposed to be. For example: With the parking brake on, Holding one wheel, the other can rotate almost an eighth of a turn before being stopped by internal engagement.

[@barntech2291]

I don’t know. I haven’t seen a differential with a chain yet. Mine has ring and pinion. That sounds pretty sloppy though

[@rodneybilly7389]

Really good video buddy I have a 11 Polaris Ranger 800 XP- h o - EFI space eps I'm getting ready to tear me down I may need some help if that's okay with you I have never disassembled one before but I'm getting ready to I may need to ask a couple questions after I get it torn down thank you

[@barntech2291]

Happy to help if I can :-)

[@kuauhtliguerrier9036]

Hola mi diferencial trasero se rompió, y no lo puedo conseguir, se puede mover el Rzr con solo el diferencial delantero? No para correlo pero si para moverlo de lugar? Saludos gracias

[@barntech2291]

When my rear differential broke it skidded to a stop from 30 mph. I was able to drive home in reverse with the front differential locked.

[@irlightbuilds1768]

Hi. I was hearing a noise from the back end of my Ranger XP 900 EPS 2015. I was told by the dealer l need a new rear diff. I think it is a bearing that has given up. Your thoughts would be very much appreciated. Where the drive shaft goes into the diff l have play up down and left and right. It still drives fine, diff is still working ok. I have a video but not sure how to post it here.

[@barntech2291]

Mine has had the same issue as yours a few times now. I think mine is because the suspension bushings are worn out. That lets one of the axle shafts come out of the diff when I flex it out. Water comes in and oil goes out. Soon after, the pinion bearings are destroyed and I have to rebuild it AGAIN.

[@irlightbuilds1768]

@@barntech2291 I am in Scotland in the UK, Dealer is saying they want the equivalent of almost $5000 to fit a new diff. I think it is just needing new bearings and seal kit fitted. I will check the suspension bushings when I get it back.

[@canisemccomb3710]

Great video! We have the same issue with our xp 700. I have a question though, how did you hold the ring/pinion so it wouldn't turn to remove the pinion nut! My husband is at that point and can't seem to figure it out! I would greatly appreciate your advice! Thank you, Canise McComb

[@barntech2291]

Thanks! It’s either in this video or my Honda Rincon video, but I partially reassembled the diff and installed the axle shafts to hold the pinion from turning.

[@canisemccomb3710]

@@barntech2291 He tried to do that first to loosen the nut but everything tried to move. He couldn't keep the wheels from climbing the stop blocks. He had an actual deep socket and a pipe wrench with a pipe on it for leverage but couldn't hold it. In this video you had the diff out and on the bench. It looked like you had pretty good pressure on the pipe wrench to loosen the nut so I assumed you had something holding the ring/pinion assembly to be able to hold them solid to apply pressure with the pipe wrench. Thank you, C. McComb

[@barntech2291]

Is the pinion nut swaged into the keyway? If so you may need to punch that back out first.

[@barntech2291]

On some of them I can jam a big screwdriver between a couple of the bolts that hold on the ring gear and use that as a prybar. On the really hard ones I use the axles to hold it still.

[@williamyeomans4737]

I have a 2016 range 900xp I need to take out the rear diff to put bearings in jm not sure how can you help?? Thanks

[@barntech2291]

Which part are you having trouble with?

[@SayMyNameOutLoud]

Can you tell me where you found the parts kit? Or a link?

[@barntech2291]

I have bought a couple different ones on Amazon. The one from Quadboss was good. Another one I got was missing a bearing.

[@williamyeomans4737]

I have a polaris ranger 900xp 2016 how do I take out the rear diff to rebuild video world be nice. Thanks

[@barntech2291]

If it is like my 2009, you have to remove the bed, emergency brake cable, and emergency brake assembly. Pop the axle shafts loose with a pickle fork, then remove the four bolts and nuts attaching the differential to the frame. The axle shafts will come out as you pull the diff out.

[@joshcisneroz5700]

Does clutch gear or dog gear is it supposed to move all over was change cv axle noticed splines moven or is there something I need replace thanks and nice video

[@barntech2291]

I think you are asking about the differential locker. The inside of the cog is splined and there is a fork that slides it in and out on the CV axle shaft. The CV axle shaft is also splined so the differential is locked when the cog is in this position but there is a section of the shaft that is not splined so the left and right axle shafts can spin independently if the cog is in this position. Did I answer your question?

[@roaddiablo]

Did you set the preload? Backlash? Gear mesh pattern?

[@barntech2291]

Not in this video, but I went back later and added shims to reduce backlash. I used plastigage to measure the gap and that got it close enough for me. The other thing I didn’t do in this video was swage the pinion nut; that’s a critical step!

[@DonaldBeard-d2s]

How do I reinstall locking pin

[@barntech2291]

If you are asking how to keep the pinion nut from backing off, I used a hammer and punch to swage the nut after assembly.

[@armedfarm3429]

Ah, and people wonder why the things go to hell. Take care of the thing. The water has been in the rear diff a long time!

[@barntech2291]

I think it only took a couple months of water to rust like that. It started when one of the axle shafts popped out a little while I was crossed up. That was the first time it happened, so I didn’t know it was taking in water.

[@happydayz5321]

Good Job BT ! What torque on the pinion nut ?

[@barntech2291]

All the torques :-) Seriously, unless you are able to lock the diff from spinning you won’t be able to get enough torque to strip it. I was using the wheels to keep it from spinning so I probably only got 75 -100 ft lbs before i couldn’t hold the cycle still. Not exact science using a monkey wrench on a fence post :-)

[@piolin3603]

Hi,sir,What is the name of this tool？

[@barntech2291]

Which tool? The pinion nut socket I made from a fence post?