Good morning all, Just a bit of history on this side x side. I was given a 1999 Polaris Ranger 6x6 with 849 hours on the meter. Previous owner said it ran when last parked. When we got it home we found that it would do nothing when the key was turned to start. (New Battery installed). Diagnosis turned out to be a bad ignition switch. Replaced. Now the S x S runs. It has low range and reverse. When trying to shift to high range, it will not completely engage. There is a little grinding as it won't completely go into gear. I found that the shift rod is hitting the front of the circle opening in the plate the shift rod comes up through. That's where we are now and the reason I am here. I have removed the plate. I have removed the shifter box. I have dissembled the shifter box. Everything inside is as it should be with the exception of the ball at the end of the shift rod. There is a small blind pin holding the ball to the shift rod. I can move the ball back and forth on the rod. I feel certain the play should not be there. It is allowing the shift rod to hit the front of the circle opening mentioned above. Thus, preventing full engagement into high range.
My question. Has anyone ever ran into this problem? How did you fix it? I am contemplating drilling out the pin and maybe taping and using an allan screw or maybe a roll pin to remove the play. I might add, there seems to be vary few parts available for this machine.
I will await and appreciate any and all replies. OT

 

No idea what your set up looks like but, Is it not more likely "the plate the shift rod comes up through" has moved, so you don't get full travel? If Eigers and King Quads get a hard enough knock on the Bull bar, the front plastic moves backwards, stopping the gear lever from going far enough forwards to engage low.

 

Thank you Merryman for your reply. I will try to post some pics of the area and related problem I am having. Possibly a video. Thank you again. OT

 

Below is a link to partzilla. It shows my problem area. I will attempt to circle the exact area. I don't know if it will allow me to do that or not. If not, it is item 8 in the diagram. The shift rod going into the ball can rotate approximately 1 1/2". I feel there should be no movement at all. OT

https://www.partzilla.com/catalog/po.../gear-selector

 

Above is a screen shot of the shift rod I am working on. The shift rod goes into the shift ball, item 8. There is a blind pin, (can not be removed and is not a through pin) that fastens the shift rod to the shift ball. With the ball in a vise, I can rotate the rod back and forth approx. 1 1/2 inches. I feel certain that this should be a solid connection. Has anyone seen this problem and if so, what did you do to repair it. I have searched and there seems to be no parts available. Thanks in advance for any and all replies. :-) OT

 

So, move the gear lever sideways and it swivels on that external pin. Move it forwards/backwards, it must swivel on the "internal" pin. The linkage between control box and gearbox has ball joints 16, 18 and 22 which are threaded so they can be adjusted to the right length. Could bad adjustment on the linkage be your problem?

 

Good morning merryman, Thank you for your reply. Part 8 (shift ball) sets down into a nylon bearing cup. The ball has two pivot pins right and left. Both 90 degrees from the blind pin. The ball can rock to the right and left. It can also pivot on the two pins. Forwards and rearward. In the shift box there are two slots which contain "centering springs". The right and left pins sit on top of those springs and hold the ball centered when in neutral. Pull the handle to the left and the very bottom of Part 8 (somewhat pointed) engages the selector slide for High and Reverse. While holding handle left and moving to the front for High or to the rear for Reverse. The selector slide connects (external) to the ball joint you refer to.
Update:
I have removed the upper band holding the rubber boot to the shift handle and slid it (boot and spring) up the shift handle shaft. That exposed the very top of the ball where the shaft enters. Low and behold, I found that the shaft had been welded to the ball at some point in time. The weld had broken and obviously the blind pin had sheared. I then through drilled the ball and shaft through the blind pin and inserted a hardened roll pin. I cleaned up the previous weld and took the whole thing to a friend to have it tig or mig welded. Not sure what he has. I would show some pics but my i phone is acting up. Anyway, the play in the handle shaft and the ball has been correct and I am on my way to getting this old thing going again. Thanks again for your interest and reply. Kindest regards, OT
PS: What I failed to mention is the fact that my original thought of the shifter shaft and the ball should be a solid connection was correct. It should be a one solid piece.

 

Shift rod and ball with old weld.

Shift rod and ball with new roll pin


Rod and ball with new weld.
Now just need to get everything back together.

 

Correct. The ball should have no movement on the shift lever shaft.
It must be pinned stationary to the shaft .

 

Red64, I through drilled and pinned with a hardened roll pin. Countersunk the pin to allow for the switch pin. Then had it welded. Got everything back together and installed yesterday. Had to adjust the linkage to the transmission which had probably been out of adjustment to begin with causing all the problems. Anyway, it works great. Thanks for the reply. :-) OT