Good Evening Everybody,

I was riding the other day when all of a sudden my sportsman made a really bad grinding noise. It seems that the one rear axle wore out the splines on the end where it goes into the rear gearcase and was slipping. I know the axle splines are shot but the gearcase splines looks to be worn some as well. Upon looking around on the internet, it seems that you can not buy just the gear (see attached picture #14), but have to buy the whole assembly for over $1000. Has anybody else run into this. I don't want to replace just the axle and mess up more because i didn't fix it right the first time, but don't want to waste a bunch of extra money either. I found a few gearcases on ebay but they are in pretty rough shape as well. Any thoughts?

Mike

 

If it helps this is a 2006 sportsman 800

 

Yes sometimes Polaris is crazy on the way parts are sold. Entirely possible that Polaris received the rear complete cases only in production and some spares and not at all the internal parts,therefore for one part you have to buy the assembly.Strange though that you can still buy the pinion shaft.Think I'd look for a good used rear diff on ebay that you could tear out the parts and use on yours.1332660 Polaris | eBay

 

 

i got new axles to replace mine but it seems that the splines in the rear gearcase are shot too. Looking around online for some OEM parts and it seems that i can get the gear i need from a 2008 but it has a different part number on it. Is it really different or did something acutally change that would keep it from working? I just need the large gear out of the rear. The part number that i need to replace is 3233879 and the one from the 2008 is 3234663. The bearings that go along with these are different numbers too. I just want to make sure i get parts that will still work in the housing that i have. I found an almost brand new complete assembly from a 2002 700 on ebay that i was thinking about too.

 

That's what SWFLMUd and I were talking about. This gear is NLA separately. It's part number is replaced by the complete gear case number. You have a choice of finding a used gear case assembly on ebay that can fix you up or bite the bullet on a new one. As far as different part numbers on the gear and bearings from different machines,stay with the gear case that fits as there can be changes. Your model along with these other year models use the same rear gear case.(1332366)This gives you more to choose from if searching used diffs for parts that fit if that's the way you wish to go.The 2002 rear diff that you found may or may not work right.

Usage : 1332366 Rear gear case (updated part number on a complete new rear gear case is #1332660 for your model)

Year Product Model Assembly
2008 ATV SPORTSMAN 800 EFI SCANDINAVIAN DRIVE TRAIN, REAR GEARCASE INTERNALS (Built 1/31/08 and Before) - A08MH76SS/SF (4999200299920029D04)
2008 ATV SPORTSMAN 800 HO EFI DRIVE TRAIN, REAR GEARCASE INTERNALS (Built 1/31/08 and Before) - A08MN76AF/AL/AQ/AR/AS/AT/AX (4999200299920029D04)
2007 ATV SPORTSMAN 700 EFI GEARCASE, REAR - A07MH68AX/AY/AZ (4999200229920022D03)
2007 ATV SPORTSMAN 800 EFI GEARCASE, REAR - A07MH76AL/AQ/AX/AY/AZ/A2/MN76AF/AT/AY (4999200299920029D04)
2007 ATV SPORTSMAN 800 EFI INTL GEARCASE, REAR - A07MH76FA (4999200299920029D04)
2006 ATV SPORTSMAN 700 GEARCASE, REAR - A06MH68AA/AD/AF (4994229422D05)
2006 ATV SPORTSMAN 700 EFI GEARCASE, REAR - A06MH68AQ/AT/AX/AY/AZ (4994229422D05)
2006 ATV SPORTSMAN 800 EFI GEARCASE, REAR - A06MH76AL/AQ/AT/AX/AY/AZ (4994229422D05)
2005 ATV SPORTSMAN 800 EFI GEARCASE, REAR - A05MH76AC/AT/AU/AW (4994229422D05)
2005 ATV SPORTSMAN 600 REAR GEARCASE - A05MH59AK/AN (4994229422D05)
2005 ATV SPORTSMAN 700 EFI REAR GEARCASE - A05MH68AC/AS/AT/AU/AW (4994229422D05)
2005 ATV SPORTSMAN 700 REAR GEARCASE - A05MH68AK/AN/AD (4994229422D05)

 

I can pull case apart tomorrow and see what it looks like and see if that part is salvagable.