A short time ago, my 2002 Polaris Ranger 4x4 started grinding when I put it into high range. I had to play with the shifter and finally it would stay in gear. A month has passed and it has just gotten worse. Today, I disconnected the linkage and shifted the lever on the tranny by hand to rule out a linkage adjustment problem. Now, it will no longer shift into high gear. It just grinds. Reverse, low and neutral are all fine.

The fluid level is good, by the way.

Has anyone dealt with this issue.

I would appreciate any help you could send my way. Thank you.

 

Sorry to say,but I have repaired what you are describing. Dog gears,forward drive gear,shift fork usually the problem! Have found some ranch and farm machines that are abused,slammed into forward from low range while still moving the most common cause.Plus running in high range at low speeds is tough on clutches and transmission. Most people dont take advantage of low range.

 

Thank you very much for the reply. Can you advise on how difficult this job is and where to get parts? I'm very comfortable turning tools, but I've not been inside of a Polaris tranny yet. Thanks for your time.

Brett

 

Not that awfull difficult,but dont pull front cover where shift arm is! Take down from back side,remove bolts,pull back cover,note position of shift forks,pull shift fork shaft,remove lower gear that powers pinion shaft, pull shafts and gears as unit on upper trans. Check for burrs on shift forks,engagement dog wear(that shift forks on) and ALL gears for wear on teeth and dogs. Check silent chain for slack,I always replace! Replace wave springs between shift fork gears always! Also check bearings for rough spots. Good luck.

 

Do you pull the transmission completely out of the machine or do you leave it bolted in and pull cover off?

 

Must be pulled out of frame. Good luck

 

ok this helped me out but i cannot find a site with the forks and gears for the ranger ,

 

Look up PURE POLARIS parts catalog, can scroll down on your machine info for parts needed. Good luck

 

I have both shafts out now. The dogs on the side of the 30T high range gear are worn down at an angle. About half way actually. This makes perfect sense now. Once they mesh, it runs in high range smoothly. Meshing is tough since there are no square shoulders on the gear for the shift collars to grab.

Anyway, you said to remove the lower gear that drives the pinion shaft. There is a bearing on the end of the shaft that I can't get behind to pull. I put a 3 jaw puller behind the gear and tried pulling the gear which in turn should also pull the bearing. I put a lot of force on it and the bearing didn't move. There's not a snap ring that holds the gear on is there? If so, I was pulling the gear into the snap ring and not into the bearing. The parts diagram doesn't show a snap ring though.

A little more detail on pulling bearings and gears and from which end would be very helpful to me.

Again, I appreciate your time in helping me out.

 

Okay, I was able to press the gear off. I can't imagine how much pressure it took, but I used a 20 ton press and was putting a lot of "arm" into it. I was afraid that the gear would shatter instead of coming off. Ready to order parts now. I liked the site you mentioned earlier in the post. Thanks.