Created: May 26, 2020
[0:00] The first thing you’re gonna do once you have your differential removed from your machine is drain all the oil out of it. Then we’re going to remove the lid by removing all the hardware securing it to the case of the machine.
Remove the lid. Sometimes they get stuck so you’ll just take a flat screwdriver and work it up underneath. We’ll go all the way around and it’ll come right off.
Then continue removing all the components from the differential. What we’re gonna do so we don’t lose all of our rollers out of our sprague is just grab a hold of our sprague and pick it straight up. Set the ring gear down on the table.
Once we’ve done that, take a rag and set it down in here so we don’t lose a bunch of oil. We do have some residual oil staying in the case here.
[1:19] Go ahead and knock the seal out of the pinion shaft. I’m gonna take a small flat-head screwdriver, get right here on the lip, and tap it straight in. Once you get it in there, pry the seal straight out.
We’re going to take a pair of snap ring pliers and remove the snap ring securing the pinion shaft to the differential. Sometimes the pinion shaft will get stuck, so you’ll need to take a pry bar, stick it right down in here on the face of the gear, and pry it straight out.
[2:31] Now we’ll head over to the press and press our bearing off of this gear and install it to our new gear. We’ll remove our snap ring and then press our bearing off.
Then we’re going to stick the pinion shaft in here, just like this, and then press the shaft right through the bearing. There’s our bearing right there.
We’ll take our stock shaft and set it aside. We’re gonna grab the new shaft that came in our ring and pinion gear set from SuperATV. We’ll do the exact opposite. We’re just gonna flip it over and press the shaft through the bearing.
You just want to press it down until it fully seats. You’ll be able to hear your press start to bind down a little bit. Once it does that, you know you’re good to go.
[3:50] We’re gonna take our snap ring and reinstall it.
You want to go around and make sure that it fully seats all the way around. A lot of times, when you take a bearing off another shaft and press it onto a different shaft, it’ll get to the point where it’ll bind up a little bit. The inner race may move just enough to the point where that snap ring won’t fully seat. We’re good enough here.
If you do have that happen, what you need to do instead of pressing the shaft through the bearing, press right here. Have something on the bottom side that holds it right on this inner race. Maybe a socket or something like that. That way it pushes that race down and gets it so it’s centered again, so your snap ring will go in.
[4:46] Now we’re gonna go ahead and install our new pinion shaft with our bearing back into the housing. I like to stand it straight up and look at it. A lot of times you can get this bearing centered and it’ll just slide right down. If not, sometimes they go crooked.
Take your mallet and work it all the way around, until it goes all the way in. You shouldn’t have to hit it very hard. If you have to beat on it then you know you’ve got something going on and you’ll want to reassess the situation there. But ours is fully seated.
While we’re here we’ll take our big snap ring and reinstall it, the same exact way that it came out.
[5:51] Like I was saying, this differential doesn’t have a whole lot of miles on it. However, you do want to make sure that your differential is super clean before you continue. You don’t want any metal shavings or anything like that in there.
This is the time for you to take your differential completely apart. The last thing would be the hub. Spray it all out and get it nice and clean, then you should be good to go.
We have our old ring gear here. We’ll set this aside. Just for demonstration purposes, we removed all the rollers out of our sprague carrier today.
We’ll knock our roll pin out of this ring gear here. Flip it over. We’re gonna grab the punch that fits down in there perfectly and take a steel hammer. Knock it straight out. It shouldn’t take much.
As you can see on the O-ring gear, there’s only one hole. On ours we added two, just in case. When you put it together, if you can’t get everything to line up properly, you can move your roll pin over to a different location so you get a good start.
We’ll just take a punch and tap it down in there. You may have to adjust it, it just depends.
One way you can check is take your torsion spring and set it down. It looks like we need to knock ours out just a little bit more. You don’t want it too far up, but you don’t want it so far down where the spring will just jump right off.
The spring is gonna hold on to that pretty tight. It’s sitting pretty much flush with the top of this spring. That’s exactly what you want. You don’t want it too high up and you don’t want it too shallow, so your spring doesn’t jump off as you’re putting it together.
[8:00] Obviously, once you put your torsion spring retainer on there, it can’t go anywhere. But it just makes installation a little bit easier.
Make sure there’s no shims or anything like that. Make sure the differential is super clean.
We’ll go ahead and take our new ring gear and slide it right down into place. Wiggle it and make sure it makes good contact with your pinion gear. Ours is good to go.
Like we said, for demonstration purposes, we don’t have any rollers on our sprague. Obviously you want to make sure all your rollers are in there. And if your sprague is damaged, you can pick one up from SuperATV.com. We have a variety of options for numerous differentials. Heavy duties and standard duties.
We’ll slide our sprague in there, just like that. Put your sprague in there. Take your torsion spring and just how we were showing you a second ago, just loop the spring over there so it sits down.
We’ll take a torsion spring retainer and make sure this stud right here fits down perfectly in between the torsion spring. We’re gonna line it up and it will just sit it right down in there. Wiggle it around a little bit. Sometimes your spring will jump off as you’re doing that, so you’ve got to be careful when you’re putting it in there.
[9:19] Now that we have that installed, we’ll grab our plate. Make sure you line it up with the rollers to the torsion spring retainer plate. Then just grab your top hub and slide it into place. Take your lid and get it reinstalled. Just make sure your lid goes down and fully seats, just like that.
Make sure your hub is fitting through your outer seal on both sides, which ours is. Then you’d have to get a new OE seal for the pinion shaft. You can get that from your local Polaris dealership.
[10:21] Like I said, this is just a demonstration, so we’re not gonna be putting the seal back in. But all you would do is just slide it right in, just like that. A lot of times you can push them in by hand. Then I recommend taking a flat punch, a pretty good-sized punch, and tap it all the way around until it goes all the way in and fully seats. Make sure it seals up on that pinion shaft.
Once you’ve done all that, reinstall your screws. Make sure you get them to factory torque specs for your differential. Some of these differentials will have Allen heads and some will actually have a hex head 10 mm. So it all depends on what your differential is.
This is an XP 900 differential, but this ring gear will also work on the various makes and models. So make sure you look at the factory torque spec.
[11:20] Get everything tightened and make sure everything’s good. Then reinstall it in your machine.
And there you have it. That’s how super quick and easy it is to install SuperATV’s Ring and Pinion Gear Set into your OE differential. For more information on our ring and pinion set or any of SuperATV’s great products, feel free to give us a call at 855-743-3427 or check us out online at SuperATV.com. Thanks for watching and we’ll catch you next time.
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