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post #1 of 13 (permalink) Old 08-22-2019, 05:37 PM Thread Starter
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Question hello & help!

Was cruising the web looking for some repair advice. Can you guys help? I have a used Polaris Ranger ETX (2015, I think). It won't switch into AWD, because the two wires that enter the front diff have clean broken off right at the diff, so I can't re-connect them to it. What do I do? Do I remove and replace the connector (or is it a magnet?) that's in the diff? If so, how??? And where can I get that part from? Please assist if you can. Thanks!
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post #2 of 13 (permalink) Old 08-22-2019, 06:07 PM
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First I think you need to clarify what you have. A Ranger and an EXT are different machines. Ranger is a side by side and the EXT is an ATV. The 10th digit of the VIN will indicate the model year. If you have the VIN or write it down somewhere there are VIN search sites that will tell you what you have or you can call a dealership and ask them to run it too.

You can get parts from a number of different sources. A dealership, however they are usually very proud of their parts. Partzilla.com, Bikebandit.com and a few other places offer Polaris parts but you have to wait longer to get them. Some stuff you can get used, from Ebay or I use a salvage yard in Nebraska...powersportsnation.com

In your case, I think you are going to have to pull the front diff apart and see if you can splice the wires. I have never been inside a front diff so I don't know how much room is inside. You might have to replace the whole electro-magnet to get it fixed. I would suggest that you get a repair manual for your machine. I rebuilt the engine in my first 325 from a Clymer manual.

Sounds like you have an interesting project! Good luck with it!

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #3 of 13 (permalink) Old 08-22-2019, 10:45 PM Thread Starter
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Question

Greetings, Steve! Thanks for your reply. I re-checked and it is still a Polaris Ranger ETX. It's 400cc, EFI. There's a two-wire connector plug on one end, and the two broken wires on the other. And the backlight on the AWD dash switch still works. So all I have is the two broken wires that need to be reconnected to the spot on the diff. Seems to me there should be an easy way to access and replace the part at that point where the two wires enter the front diff - without having to split the case. How is that electromagnet fitted???
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post #4 of 13 (permalink) Old 08-23-2019, 04:58 AM
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Your going to have to pull the diff, open it up, and replace/repair the wires. That's it in a nut shell!!

2011 Sportsman® 800 EFI
GURU front brush guard
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Polaris front lock n ride cargo box
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Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
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post #5 of 13 (permalink) Old 08-23-2019, 05:10 AM
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Yep - the only fix requires removing and disassembling the front gearcase - not easy and can't be done quickly, but I would like to know what you are working on. A Ranger or an ETX? It might make a difference on the parts needed or the disassembly and assembly techniques. What's the VIN?

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post #6 of 13 (permalink) Old 08-23-2019, 05:44 AM
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Ok, I am not familiar with the EXT model of the Ranger line. Never saw one before. I put them together for a dealership so we must not have sold any.

It is a Ranger, the engine size doesn't really matter in this case and bp405 is on the money, you will have to pull the diff and repair the wires. Not an real difficult procedure, but it won't be a quick one. You will pretty much need to take the whole front suspension apart to get to the diff.
Most of it should be fairly self explanatory but you will be much farther ahead to have a repair manual in the long run. It will give you step by step instructions for getting the diff out, apart, repaired and back together.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #7 of 13 (permalink) Old 08-23-2019, 10:35 AM Thread Starter
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I was afraid you were gonna tell me that! Trying to do this on the quick and easy. Is it worth trying to "excavate" around the connection point with a rotary tool to expose the wires for a patched reconnect? I'm not happy that such thin gauge wires were used here. A little mud and a few bumps and the wires no doubt will simply stress-fracture off soon enough again. BTW, you guys are awesome!
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post #8 of 13 (permalink) Old 08-23-2019, 01:34 PM Thread Starter
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Exclamation

P.S. The VIN is 3NSRMA322FE368743.
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post #9 of 13 (permalink) Old 08-23-2019, 02:01 PM
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You, Sir, indeed do have a RANGER® ETX - SAGE GREEN in color, 2015 model # R15RMA32AA purchased on 11/30/2015 engine # 0120498303217 and the warranty expired 11/30/2017

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post #10 of 13 (permalink) Old 08-23-2019, 03:23 PM
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No, do not excavate and half ass the repair. The front diff is pretty well protected in there behind the brush guard and all. So I would guess this issue is an isolated incident. Shit happens sometimes no matter how well we plan for everything.

The front diff has to stay sealed so if you dig around with a dremel, you could compromise the case and cause a leak. You are only looking at a few hours work here. They are not that complicated it just takes time to get into where you need to get. Do the repair right the first time. Worst case you will need to get the electro-magnet inside if there isn't enough room to add a splice. The splice will need to be sealed from the fluids inside the diff so maybe a solder joint and shrink tubing.

I would say you should be able to get this repair done properly in a day. Work outside in from the wheels into the diff and take your time. You can do this man!

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
stave7119 is online now  
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