do you remeber motof150 guy?? enough said lol.

 

Oh my God...........Really your saying that!!!!!..........Well it time to put my Manual down......Sorry guys...............It just too much reading at once!!!!..........LOL..LOL....Maybe a new tip next week............Sorry .......Caper............

 

Do you remember the guy that called us stupid when we said the roller cage in the polaris front diff was made of plastic/nylon. He had only ever worked on the older polaris models where the AWD engaged in the Hubs and not the diff and I believe the cage is aluminum.

 

What year did they change the front hub set-up..........Like the ones we have now.......Thanks....Caper.....

 

The 2002 700 had the AWD in diff, all other in Hubs
2003 600 and 700 in diff
2004 600 and 700 in diff
2004.5 all went to diff except scrambler
2005 to present use it in diff except scrambler I think.

Rangers are a different story.

 

Did you work on both?.......Which one do you think is better.......Let me guess new one?
Some people don't like change though!!!...Thanks.....Caper.......

 

I think the new system (diff) is a good one and the changes they made for 2007 should fix previous problems. The drive shaft angel has been reduced as it enters the diff (all 2007 sportsmans) by making the input shaft enter the diff at an angle other than 90 degrees to the output shafts. So this should decrease the vibration which leads to some front diff engagement problems (how I would explain it). One thing I will point out is that I rarely see problems with polaris ranger front diffs. I dont know if it's because they have a reduced angel where the input shaft enters the diff or the fact that their is no override for the AWD to work in reverse (the AWD engages when shifted). My next mod will be to reomove that override switch so I dont push it at the wrong time and engage my front diff while the rear wheels are spinning. I have had no problems with my 2004.5 500 or 2006 800 because I learned early on what will happen to the front diff if it engages while the rear wheels are spinning. From looking at diffs through the years polaris is trying to get their system right. Just my openion.

 

Humm....So the front shaft angle on my 2006 sportsman 450 is different than the new 2007 sportsman 450.........Correct.......How much?......I didn't know that change was made!!....Caper.....

 

I'm not a subject matter expert and I shouldn't say all, and these are just my observations through the years on the diffs.

I remember looking at the 2007 models and noticing smaller front CV shafts and a different diff. The shaft still comes to the diff input shaft at the same angle, but the input shaft of the diff sticks out rerward at an angle other than 90 degrees to the output/CV shafts. I would think you could do the mod with a different front drive shaft, diff, and CV shafts, but who knows about the transmission front output shaft and front hubs. Oh yea was looking the other day and I noticed the 2007 models have different fornt stuts. I didn't see grease zerks on the lower ball joints anymore. While after 20 years of the MacPherson front struts system thay had to change something.

 

Yes I forgot about the front strut change....I need to drop in at the dealer and take a look......Caper.............