i have a 2005 sportsman 400 that needs a front diff, are there other brands/makes that will fit or does it have to be polaris only? thanks.

 

Best to keep the same style diff,less problems. Plus is just the roll caged damage or the insides totaled like I've seen a few over the years? You can find a used one if need be and rebuild it and probably come out cheaper if yours is trashed out. Also depends on the build date as to which gear case you have.
Machines built before 6/13/05 used #1341497 front diff. Machines built after 6/13/05 used diff #1332428. Different years and model machines did share each one. Hopefully you still have the sticker on the front diff or possibly have the build sheet that came with the paperwork and owners manual..
Usage : 1341497 Front Housing

Year Product Model Assembly
SERIES 11 PPS UTV 2X4/4X4/6X6 FRONT HOUSING - C11RD50AA/AB/C11RF50AA (4981898189D04)
2005 ATV MAGNUM 330 4X4 FRONT HOUSING - A05CD32AA/AB/AC (4994909490C06)
2005 ATV ATP 330 4X4 FRONT HOUSING - A05JD32AA (4995169516C12)
2005 ATV ATP 330 4X4 QUAD FRONT HOUSING - A05JD32EA (4995169516C12)
2005 ATV ATP 500 4X4 FRONT HOUSING - A05JD50AA/AB/AC (4995169516C12)
2005 ATV SPORTSMAN 400 FRONT HOUSING - A05MH42AB/AG/AH (4994229422D04)
2005 ATV SPORTSMAN 500 HO/INTL FRONT HOUSING - A05MH50AB/AC/AG/AH/AL/AT/FB (4994229422D04)
2005 ATV SPORTSMAN 600 FRONT HOUSING - A05MH59AK/AN (4994229422D04)
2005 ATV SPORTSMAN 700 EFI FRONT HOUSING - A05MH68AC/AS/AT/AU/AW (4994229422D04)
2005 ATV SPORTSMAN 700 FRONT HOUSING - A05MH68AK/AN/AD (4994229422D04)
2005 ATV SPORTSMAN 800 EFI FRONT HOUSING - A05MH76AC/AT/AU/AW (4994229422D04)
2005 ATV SPORTSMAN MV7 HOUSING, FRONT - A05MH68AP (4999609960D05)
2005 MIL SPORTSMAN MV 7 GEARCASE, FRONT - A05MH68MB (4999609960D05)
2005 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4)(6X6) - R05RD50AA/AB/AC/AD/RF50AA/AB (4995359535E02)
2005 RGR RANGER XP HOUSING, FRONT - R05RD68AA/AB (4998269826D03)
2004 ATV MAGNUM 330 4X4 FRONT HOUSING - A04CD32AA/AB/AC (4994909490C06)
2004 ATV A04CH42AQ SPORTSMAN 400 FRONT HOUSING - A04CH42AQ/AR/AS/AT/AV (4987258725D01)
2004 ATV A04CH50AQ SPORTSMAN 500 FRONT HOUSING - A04CH50AO/AQ/AR/AS/AT/AV/AW/AX (4987258725D01)
2004 ATV A04CH59AK SPORTSMAN 600 FRONT HOUSING - A04CH59AK/AL/AN/AQ/AW (4987258725D01)
2004 ATV A04CH68AK SPORTSMAN 700 FRONT HOUSING - A04CH68AK/AL/AN/AO (4987258725D01)
2004 ATV A04CH68AU/CU SPORTSMAN 700 FRONT HOUSING - A04CH68AP/AQ/AU/CU (4987258725D01)
2004 ATV ATP 330 4X4 FRONT HOUSING - A04JD32AA (4987258725D01)
2004 ATV A04JD50AA ATP 500 4X4 FRONT HOUSING - A04JD50AA/AB/CA (4987258725D01)
2004 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4) (6X6) - A04RD50AA/AB/AC/A04RF50AA (4987918791D02)

Usage : 1332428 Front Housing

Year Product Model Assembly
2008 RGR RANGER 6X6 700 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RF68AD/AF/AZ (4999202259920225D03)
2008 RGR RANGER 4X4 500 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH50AF/AR/AT (4999203249920324D03)
2008 RGR RANGER 4X4 700 EFI/XP ALL OPTIONS DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH68 ALL OPTIONS (4999202259920225D03)
2007 RGR RANGER 500 2X4/4X4 GEARCASE, FRONT - R07RB50AA/RH50AA (4995359535E02)
2007 RGR RANGER 700 EFI 6X6 GEARCASE, FRONT - R07RF68AD/AF (4999202259920225D03)
2007 RGR RANGER 500 EFI 4X4 GEARCASE, FRONT - R07RH50AF/AR/AT (4999203249920324D03)
2007 RGR RANGER 4X4 700 EFI/LE GEARCASE, FRONT - R07RH68AD/AG/AH/AK/AL/AO/AP/AW (4999203249920324D03)
2006 ATV MAGNUM 330 4X4 HOUSING, FRONT (DEMAND DRIVE) - A06CD32AA/AB/AC (4999201699920169C03)
2006 ATV SPORTSMAN 450 HOUSING, FRONT (DEMAND DRIVE) - A06MH46 ALL OPTIONS (4999201699920169C03)
2006 ATV SPORTSMAN 500 HO HOUSING, FRONT (DEMAND DRIVE) - A06MH50AA/AB/AD/AF (4999201699920169C03)
2006 ATV SPORTSMAN 500 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH50AQ/AX/AY/AZ/AL/AT (4999205499920549D03)
2006 ATV SPORTSMAN 500 HO INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FB (4999201699920169C03)
2006 ATV SPORTSMAN 500 EFI INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FC (4999205499920549D03)
2006 ATV SPORTSMAN 700 HOUSING, FRONT (DEMAND DRIVE) - A06MH68AA/AD/AF (4999200179920017D03)
2006 ATV SPORTSMAN 700 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH68AQ/AT/AX/AY/AZ (4999201699920169C03)
2006 ATV SPORTSMAN 800 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH76AL/AQ/AT/AX/AY/AZ (4999201699920169C03)
2006 RGR RANGER 500 2X4/4X4 HOUSING, FRONT (4X4) - R06RD50AA (4999202119920211D03)
2006 RGR RANGER 500 4X4 EFI HOUSING, FRONT - R06RD50AB/AC (4999203249920324D03)
2006 RGR RANGER XP 4x4 700 HOUSING, FRONT - R06RD68AA/AB/AC/AD/AE/AF (4999202219920221D03)
2006 RGR RANGER 6x6 EFI 700 HOUSING, FRONT - R06RF68AA (4999202259920225D03)
2005 ATV MAGNUM 330 4X4 FRONT HOUSING - A05CD32AA/AB/AC (4994909490C06)
2005 ATV ATP 330 4X4 FRONT HOUSING - A05JD32AA (4995169516C12)
2005 ATV ATP 330 4X4 QUAD FRONT HOUSING - A05JD32EA (4995169516C12)
2005 ATV ATP 500 4X4 FRONT HOUSING - A05JD50AA/AB/AC (4995169516C12)
2005 ATV SPORTSMAN 400 FRONT HOUSING - A05MH42AB/AG/AH (4994229422D04)
2005 ATV SPORTSMAN 500 HO/INTL FRONT HOUSING - A05MH50AB/AC/AG/AH/AL/AT/FB (4994229422D04)
2005 ATV SPORTSMAN 600 FRONT HOUSING - A05MH59AK/AN (4994229422D04)
2005 ATV SPORTSMAN 700 EFI FRONT HOUSING - A05MH68AC/AS/AT/AU/AW (4994229422D04)
2005 ATV SPORTSMAN 700 FRONT HOUSING - A05MH68AK/AN/AD (4994229422D04)
2005 ATV SPORTSMAN 800 EFI FRONT HOUSING - A05MH76AC/AT/AU/AW (4994229422D04)
2005 ATV SPORTSMAN MV7 HOUSING, FRONT - A05MH68AP (4999609960D05)
2005 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4)(6X6) - R05RD50AA/AB/AC/AD/RF50AA/AB (4995359535E02)
2005 RGR RANGER XP HOUSING, FRONT - R05RD68AA/AB (4998269826D03)

 

no paper work, bout it used about a year ago. front diff cage was broke on one side and part of what i believe is a magnet is broke off. gears look ok, all bearings are shot and the pinion shaft has groves in it. not sure if it's rebuild able.

 

Try this vin# search with the 17 digit vin# located on the lower left a-arm.ATV VIN Check - Free ATV VIN Decoder If it doesn't give you the build date then try a local dealer. Then you can tell which front diff you need and look a used one up on google search or ebay. If a used one can at least be guaranteed to be rebuildable,this might be a better option than paying over 1100 bucks for a new one.

 

hey thanks, i tried that decoder but it doesn't seem to be working ( only set up for Yamaha ). how much different are the gear ratios in these things ?

 

See if this one works.Polaris VIN Decoder, Lookup and Polaris VIN Check Gear ratios aren't given. Probably not a big difference between the two differentials as more than likely just minor changes.

 

thanks, that link was pretty vague and pretty much only told me what i already new ( year make, model, ). no specifics of any kind. appreciate the help. guess i'll have to find time to see the polaris dealer .

 

Dealer then as they have the full break down on your machine right at their finger tips..

 

how does the pinion shaft/bearing assembly come out? does it require a special puller ?

 

Once the input cover is removed,should come out easily. Item#17. Plus here's the best 5 bucks you can spend since you bought this machine used. Will more than pay for itself on any repairs and also service. 2005 Polaris Sportsman 400 Service Manual PDF Download