Hey I wondering if there has been anybody who has done a transmission swap on a 500HO Scrambler for the Sportsman 500HO transmission. Maybe aside from having to make a few brackets the thing should fit right, I would just have to make sure that the distance between the drive and driven clutch is correct and also the alignment. This would give me the LO/HI range that I want be in a sport chassis. [img]i/expressions/face-icon-small-smile.gif[/img] [img]i/expressions/face-icon-small-smile.gif[/img] [img]i/expressions/face-icon-small-smile.gif[/img]

 

The Sportsman trans wont work. It it shaft drive front and rear. You need an Explorer trans along with the linkage

 

You need to use an explorer 400 trani only. It has the same gear ratio as the scrambler, except it has low range. The other explorer tani's have weaker gears and a different gear ratio. the 400 is a direct bolt in, except for the linkage. I bent the linkage for the forward and reverse into a little of an arc to clear the starter. Then made a seperate shifter arm that goes under the seat. The only down fall is you have to have the standard shifter in neutral to shift into low. I did this conversion and installed 26" mudlites on C6 rims. Let me know if you have anymore questions.

 

i was thinking about doing the same thing, would i use the explorer tranny in my 04 scrambler??

 

Yes, mine is a 2004 also. I'm still finishing the project. But the trani bolted right in. Just make sure when putting in the trani you line it up properly. Unfortunally the polaris repair manual doesn't go into it properly. HPD does though. When i ordered the kevlar belt from them, it came with instructions that were very helpful, more so than the factory manual. Good luck and ask if you need ore help.

 

I'm hunting around for a Xplorer tranny to do this swap now. Do you know what years will work? It would help to know that when I call a salvage yard. They want to know what year I have... no, that's not exactly gunna help guys [img]i/expressions/face-icon-small-wink.gif[/img]

Where do I find more info on installing (lining it up) correctly?

 

I know a 2001 will work. Just go polaris's web site and look up the different year explorer's and check part numbers. I know you have to use a 400 as the other size engine have a different trani.

 

I'm getting ready to buy the tranny for the low range and I'm just trying to make sure I get it right.

When I look at trannys for 2001 on the xplorer, it says "GEARCASE (If built after 4/01/01)- A01CG38CA
GEARCASE (If built before 4/01/01)- A01CG38CA"

so I don't know what the difference between the two are.

Also, since my scrammy is a 2004, and it has concentric drive, is this maybe the cutoff for when they started putting in concentric drive trannys?

if I go to a 2002 to look it up, they have a xplorer 400, and a xplorer 4x4. I assume therefore that the 400 would not be a 4x4?

edit: Okay, i figured out that they're both 4x4s, but they do have different part number for the trannys. the "400" is a 1341379 and the "4x4" is a 1341381.

Mike

 

You want to use the 1341379, that is the one I did all the comparison on to the scrambler trani. The other 1341381 is for the 250 expedition and all though it had better gearing the gears looked weeker. So use the 1341379. As far as that built before one in 2001, I don't have a clue. The 2002 also used the 1341379. Mine is in and works great. The only other problem I ran in to was the air filter box doesn't fit with this trani. You need to notch out the right rear corner and use some plastic epoxy and reglue the corner in upside done to clear the low range shifter. Also when you get the trani you have high forward, normal reverse and low forward. There is no low reverse. I don't know if you new that, I didn't til I got the trani. Good luck and have fun.

 

Mr. Toys...

Thanks for the reply. What did you use for the shifter? I would assume that you bought the xplorer shifter (1341289) and the low linkage (7061013 x2) + (7546702 x2) + (5020743) to do the shifting.

Where'd you get your best deal on the tranny? polarisOEMparts.com has it for $984.99 shipped.

Mike