1996 Sportsman 500 Front differantial replacement
 

Bringing back a neglected, but surprisingly great condition 1996 Polaris sportsman 500 4x4. Been going through it the last few days. Last on my list is the front differential, it needs replaced, I have a used unit that should be here by Saturday. The whole front is accessible because its apart to replace a cracked radiator, but im holding off on that until the diff is done.

I have already been spraying stuff down with pb to help break stuff loose. There is very limited info on the removal of this online, I dont have a manual. So hoping someone can tell me the best way to do this.

As far as shaft removal, could I pull the whole a-arm, shock assembly, cv shaft as one? Will the diff pull out from the front, or does the shaft from the rear have to be completely removed?

I think im going to tear into it tomorrow, any input would be appreciated. Thanks in advance.

Just drop the a arm from the ball joint,remove the tie rod ends from the strut,pull them strut out enough to wiggle the drive shafts out. After that it's just unbolting the four bolts and wiggling the diff out. Generalized,but the basics. Plus look at several videos on youtube.

This was an absolute breeze, dreading this job for nothing.

Pulled radiator and fan, dropped a-arms, popped tie rod ends. That was it, from the time I started unbolting the radiator to the time the diff was out was less than 45 minutes.

Biggest help was the 48 hours of pb blaster, you could see where it soaked into the splines. With out it, I know I would still be fighting it, as crusty as they were. So if anyone has this project coming up, spray it down with pb a few times over a decent period of time, I guarantee it will make all the difference in the world.

Usually happens when you look at the job for the first time dreading what might happen. Then to find out the actual work was nothing that you thought it would be.I've done that many times myself. Glad it worked out good for you.

Diff came in a day early, was pretty exited but naturally, they sent the wrong one!!!

96 and 97 used the same front diff. What one did they send?

Old broken one on the top. New one or the bottom. Is there an interchange list anywhere online?

Attachment 13559

Usage: 1341154

Year Product Model Assembly
1997 ATV XPLORER 500 FRONT HOUSING XPLORER 500 W97CD50A (4941354135C011)
1997 ATV Swedish Sportsman 50 FRONT HOUSING - W97CH50A (4939993999C012)
1997 ATV SPORTSMAN 500 FRONT HOUSING - W97CH50A (4939993999C012)
1996 ATV SWEDISH SPORTSMAN 500 FRONT HOUSING SPORTSMAN 500 W969244 and SWEDISH SPORTSMAN 500 S969244 (4936093609C010)
1996 ATV SPORTSMAN 500 FRONT HOUSING SPORTSMAN 500 W969244 and SWEDISH SPORTSMAN 500 S969244 (4936093609C010)

Looks like they sent one for a 98/99 model...

Usage : 1341257 (substituted by 1341323)

Year Product Model Assembly
1999 ATV SPORTSMAN 335 FRONT HOUSING - A99CH33CB (4945964596c013)
1999 ATV SPORTSMAN 335 FRONT HOUSING - A99CH33CB (4945964596c013)
1999 ATV SPORTSMAN 335 FRONT HOUSING - A99CH33IA (4949884988c013)
1999 ATV SPORTSMAN 335 FRONT HOUSING - A99CH33IA (4949884988c013)
1999 ATV WORKER 335 FRONT HOUSING - A99CH33IA (4949884988c013)
1999 ATV DIESEL FRONT HOUSING - A99CH45CA (4949154915D003)
1999 ATV INTL DIESEL FRONT HOUSING - A99CH45CA (4949154915D003)
1999 ATV SPORTSMAN 500 RSE FRONT HOUSING - A99CH50AC (4952455245c013)
1999 ATV SPORTSMAN 500 FRONT HOUSING - A99CH50EB (4949114911c014)
1999 ATV SPORTSMAN 500 FRONT HOUSING - A99CH50EB (4949114911c014)
1999 ATV WORKER 500 FRONT HOUSING - A99CH50EB (4949114911c014)
1999 ATV WORKER 500 FRONT HOUSING - A99CH50EB (4949114911c014)
1999 RGR RANGER FRONT HOUSING - A99RF50AA (4946494649D002)
1998 ATV SWEDISH SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SWEDISH SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SPORTSMAN 500 FRONT HOUSING - S98CH50E(B) (4950135013d002)
1998 ATV SPORTSMAN 500 FRONT HOUSING - W98CH50AB (4945714571c013)
1998 ATV SPORTSMAN 500 FRONT HOUSING - W98CH50AB (4945714571c013)

Yep, those are the exaxt numbers on them. Now im sure they will want it sent back before they send the right one.

Just send a pic of your diff and part# when you send the other one back.. No excuses from them after that if it was to happen again.. :)