Can anyone tell me how to decode the transmission ID numbers. I am working on a 2004 Ranger and I know someone has been in before me. I suspect the transmission may have even been replaced and thought maybe I could tell by the numbers. There are also timing marks on the gear for the shift drum and the gear for the shift shaft. With the shift drum turned fully clockwise (reverse) the alignment mark is only in about the 7 o'clock position and the manuals I have look like it should be closer to 9 o'clock. At 7 o'clock the alignment marks will never line up. Any thoughts on this would be appreciated.

 

Which model Ranger?

 

Don't know if this helps. Here's one for the 4x4:

Usage : 1341486

Year Product Model Assembly
2004 RGR RANGER 2X4,4X4,6X6 GEARCASE - A04RB42AA/A04RD50AA/AB/AC/A04RF50AA (49RGRGEARCASE04)

The 2x4:

Usage : 1341485

Year Product Model Assembly
2004 RGR RANGER 2X4,4X4,6X6 GEARCASE - A04RB42AA/A04RD50AA/AB/AC/A04RF50AA (49RGRGEARCASE04)

And 6x6:

Usage : 1341487

Year Product Model Assembly
2005 RGR RANGER 2X4,4X4,6X6 GEARCASE - R05RD50AA/AB/AC/AD/RF50AA/AB (If Built Before 10/11/04) (4995359535E03)
2004 RGR RANGER 2X4,4X4,6X6 GEARCASE - A04RB42AA/A04RD50AA/AB/AC/A04RF50AA (49RGRGEARCASE04)

As far as individual serial numbers,might be hard to tell if it's stock or been replaced on these early models. If I remember correctly cable adjustment was either two bolts under the dash and also at the cable mount on the gear case. May or may not help on alignment of the belcrank and shift shaft.

 

Thanks OPT. It's a 2004 Ranger 500 4X4

 

This list from Polaris just gives general numbers. May be hard to tell if you have the oem gear case or it's been swapped.

 

I have the side cover that is over the shift shaft and shift drum gears removed. There was extensive water damage to the shift shaft and the gear sector #3233832. The splines on the shift shaft #3233831 and the gear sector were bad enough that the gear would actually turn on the splines a little bit. I have new parts to replace all the assemblies under the cover. My problems at this point are that I can't seem to get the gear sector #3233839 on the shift drum shaft to come off the shaft. The splines on the shift drum shaft and the sector gear on it don't look as bad as the shift shaft assembly. I am thinking I can just replace the shift shaft and it's related parts and the lockout disc and detent star along with the detent pawl and spring. The manuals for this transmission show alignment marks on the sector gears. The mark on the shift drum gear is at the 9 o'clock position and the shift shaft gear is at the 3 o'clock position. When I turn the shift drum shaft all the way clockwise (reverse) the alignment mark only goes to about the 7 o'clock position. Any thoughts on this? And how would I go about aligning the gears if I can't get the marks together?

 

Only way I can think of is to lock the shaft in a vise and use heat and penetrant. May take a small slide hammer to remove the selector as over time these parts can rust together. As far as the shift drum not being able to turn far enough,could be an internal problem.These big wide shift forks and wave springs in between the slider gears gears can cause binding on the drum if worn.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Transmission is still in the vehicle. Can't get a vise or heat on it and the raised edge around the gears where the gasket seals keeps me from getting a gear puller on it. Heat would destroy the seal behind the gear on the shift drum shaft.

 

Don't know if this helps,but look at this guy's work.Same style gear case shifter on the 700.Hard to Shift 700 Sportsman 2004 - Polaris ATV Forum

 

Thanks OPT.