I have finally started back together with the front differential in my 02 Magnum. I need to replace 1 of the output cover bolts and am trying to find specs on it. I believe it is a metric bolt M-8, 1.25 that is 25mm long. I don't know what grade it is. It has an I, C, and F I believe marked on the head. Polaris part number may be 3233918. A kit of 11 is part number 3233955. Also trying to match up the drain plug washer, part number 3233940. Local auto supply has been useless. Any cross reference numbers or specs would be greatly appreciated.

 

Grade 5 bolts have 3 marks or lines on the head that are in the shape of a “Y”. Grade 8 bolts have 6 marks on the head. Sounds like you need a grade 5..

Plus in every manual there is a general torque settings for different size bolts in the first chapter on General Information/Maintenance. They don't have enough room to list torque specs on every bolt and nut or manuals would be twice as thick.



STANDARD TORQUE SPECIFICATIONS
The following torque specifications are to be used as a general guideline. FOR SPECIFICTORQUE VALUES OF
FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering,
suspension, and engine sections.
Bolt Size Threads/In Grade 2 Grade 5 Grade 8
Torque in. lbs. (Nm)
#10 - 24 . . . . . . . . . . . . . . 27 (3.1) . . . . . . . . . . . . . . . . 43 (5.0) . . . . . . . . . . . . . . 60 (6.9)
#10 - 32 . . . . . . . . . . . . . . 31 (3.6) . . . . . . . . . . . . . . . . 49 (5.6) . . . . . . . . . . . . . . 68 (7.8)
Torque ft. lbs. (Nm)*
1/4 - 20 . . . . . . . . . . . . . . 5 (7) . . . . . . . . . . . . . . . . . . 8 (11) . . . . . . . . . . . . . . . . 12 (16)
1/4 - 28 . . . . . . . . . . . . . . 6 (8) . . . . . . . . . . . . . . . . . . 10 (14) . . . . . . . . . . . . . . 14 (19)
5/16 - 18 . . . . . . . . . . . . . . 11 (15) . . . . . . . . . . . . . . . . 17 (23) . . . . . . . . . . . . . . 25 (35)
5/16 - 24 . . . . . . . . . . . . . . 12 (16) . . . . . . . . . . . . . . . . 19 (26) . . . . . . . . . . . . . . 29 (40)
3/8 - 16 . . . . . . . . . . . . . . 20 (27) . . . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . 45 (62)
3/8 - 24 . . . . . . . . . . . . . . 23 (32) . . . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . 50 (69)
7/16 - 14 . . . . . . . . . . . . . . 30 (40) . . . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . 70 (97)
7/16 - 20 . . . . . . . . . . . . . . 35 (48) . . . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . 80 (110)
1/2 - 13 . . . . . . . . . . . . . . 50 (69) . . . . . . . . . . . . . . . . 75 (104) . . . . . . . . . . . . . 110 (152)
1/2 - 20 . . . . . . . . . . . . . . 55 (76) . . . . . . . . . . . . . . . . 90 (124) . . . . . . . . . . . . . 120 (166)
Metric / Torque
6 x 1.0 72-78 In. lbs. . . . . 8 x 1.25 14-18 ft. lbs. . . . . . . 10 x 1.25 26-30 ft. lbs.

Correct drain plug washers can be a pain to find... Had the same problem on finding the correct drain plug washer on the wifes' Saturn Vue with a Honda 3.5 engine. NO parts store could match it up. Had to go to a Honda dealer and bough a pack of 5 for an Accura MDX with the 3.5 engine.. The dealer is probably your best bet on this if you don't want it to leak.

 

Thanks OPT. Torque specs are 14 ft.lbs. Bolt head is a 13mm. Pretty sure it was 8 X 1.25 X 25mm. The head of the bolt has 4 lines and no numbers, just a "C" and an "F". I couldn't find any interpretation of the markings that would tell me what grade it was. Local Polaris dealer is 60 miles away and nobody (ebay) lists just the drain plug washer. They want to sell the drain plug kit/assembly (3233951). Prices range from $20-$30. Kinda pricey for a .75 cent washer. Local parts house did have a copper washer, any thoughts on that other than I guess you would have to change it every time you changed fluid.

 

If in doubt on grade always go with the higher grade(8) if available.Not that much difference in cost. Problem is a lot of places unless you have a good hardware nuts and bolts place is the flange bolt.They'll have plenty of the hex head,but in some cases may not have the flange bolt in your length and size.On this you could use a thin washer underneath. The drain plug washers are your call cause I've already been through this myself on the Saturn engine. Main thing with any aftermarket washer is to keep any eye out for any leaking. If you find something you can live with next chance you can get to that dealer tell him how far you had to come and he might cut you a better deal on several spares. I would have if you'd have come into our shop..

 

I looked up your part number and unfortunately it comes back as not available from the online dealer, like they no longer sell it.

Do you have an ACE Hardware or True Value near by? On hard to find stuff I usually check there as they have a good selection of odd or hard to find things.

Not an ATV but on 2 cars, one uses an aluminum washer and the other uses a copper washer. Commonly called crush washers. Typically they are like a 1/16" thick maybe slightly thicker and about the size of the flange on the bolt or just a hair larger than the flange. I'm assuming that would be the case here. As long as you were to torque it to specs they never leak.

If real desperate, go down to the auto store where they carry the oil filters, look up a filter for a BMW or a VW. These filters are usually a drop in type and in the box usually comes a large rubber gasket, the filter and most come with a crush washer in the kit. If you are lucky maybe this washer would be the right size, then just buy the filter for $5 and pitch what you don't need.

Just found this, not sure it it fits your application thread wise, but looks like something that would work if it threads and right sized bolt.
http://www.ebay.com/itm/Dorman-65324...hItv7w&vxp=mtr