See if these help.FRONT DIFFERENTIAL BEARING & SEAL KIT POLARIS 2003 2004 2005 SPORTSMAN 600 4x4 | eBay REAR DIFFERENTIAL BEARING & SEAL KIT POLARIS 2005-2006 SPORTSMAN 800 TWIN EFI | eBay

 

Wow!!! Rear diff!! Now I've never had to work on a Differential so be easy on me. Is this salvageable?? Beaeings, seals and bushings? Obviously some extensive cleaning or would I need to buy a used unit on ebay? I'd imagine the used unit would also probably need bearings etc. They are about $250+ on ebay and bearings etc unknown.

 

Picture is worth a thousand words. Don't even know if the complete rebuild kit can save this diff or not.New ones are around 1000 bucks or more and you can't trust used ones on ebay.All depends if you want to tie that much into it.

 

I haven't had any time to do anymore than split the case, how exactly does it come apart? I'm going to soak it and clean it up and then determine from there whether or not rebuild can save it. What can I use for cleaner to soak it in? I was thinking hot water with some cleaner mixed in, also what can I use to clean any grime or grit off the gears that won't damage. Steel wool? Scotch Brite ?

 

Good old steel scrub brush like we had in the parts cleaners should be ok. Soapy water sure isn't going to hurt it at this point.Followed by some spray brake cleaner.Here's a video on a Rzr. Look starting at the 9:00 mark.If it's not worth salvaging then taking a chance on a used one would be next along with the rebuild kit.

 

Round 1 of cleaning done. Third picture, around the shaft is that seal metal? All the other seals have been rubber. How do I remove this seal to pull the shaft out? Also it was definitely filled with a grease gun at some point, I got 90% of it out so far. I think I should be ok to rebuild this unit depending on how bad the housing is worn from the bushing at the end of the shaft.

 

Oem seals can be metal backed or rubber. Oem repair kit seals are rubber backed. Good job for dry wall screws and vice grips or a small slide hammer that can pop it out.

 

I tried the screws tricky, it didn't work. I had to use my Dremel and cut slits into it and grab ahold of it with vise grips. I got the snap ring out buthe now I'm trying to figure out how to get the shaft and bearing out now lol. Sprayed it down with pb blaster and waiting now. How the hell do you get it out if it's seized to the housing

 

Heat and PB Blaster or Liquid Wrench.The bearing on the shaft is probably corroded to the case.

 

This kit also has 2 bushings and this one has 4 seals? I only see 3 desks and 1 bushing in the parts diagram. Can anyone shed some light on this so I can get it ordered, thanks for the help

This is the kit but im not sure why there are 2 bushings?

Got it all apart. That was fun. There wasnt even a bushing on the end of the shaft. Now do you guys go with the All ***** bearing kit or do you just buy the bearings and seals from local bearing shop? Not sure which route would be better as far as price and quality, not looking to buy the oem at $270 shipped for everything I need. I'm trying to find a new retaining ring, minetc was stuck in there so I had to work it out with a couple screwdrivers and it is now bent. Polaris wants $33 for one