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Discussion Starter #1
OK, so here is the deal.... While pulling something in the snow my 4 WD was not engaging until I was spinning the rear wheels at high RPMs, Then it seemed to slam into gear. After trying to figure it out I took to my local Polaris dealer for a diagnosis. They say all it needs is $1,100. :yikes:
At first they started to price out a rebuild on the front diff, then decided that it would be less expensive to just put in a whole new differential. I was planning on doing the work myself and looked up a new diff for the low low price of $985, Still to much unless I plan on sleeping in the garage with it. I did a cross reference on what other machines used that same differential thinking I would look for a used one....
DRIVE TRAIN, FRONT GEARCASE and MOUNTING Part #1332909. It would seem that they used this in 2008 for my machine and then not again until 2011 when they put it in an 800 6x6 and about 10 others between 2011 and 2014. So my question... Did they change this part sometime between 08 and 2011? Is there some way to cross reference an older machine. Or would I need any special tools to do a rebuild myself?

I have read about using John Deere parts for doing a rebuild but from what I can tell that possibility ended with the 07 units.
Any help would be appreciated.
 

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Where did you get that part number? It don't match up to a 2008. It's for 2011 and up. Here's what crosses for the 08 part #1332568. There was some changes made to an internal part that year but nothing major.


Year Product Model Assembly
2009 ATV SPORTSMAN 800 EFI 6X6 DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09CL76AA
2009 ATV SPORTSMAN TOURING 500 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09DN50AB/AZ
2009 ATV SPORTSMAN TOURING 500 EFI QUAD DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09DN50EA
2009 ATV SPORTSMAN TOURING 800 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09DN76AB/AL/AY
2009 ATV SPORTSMAN TOURING 800 EFI INTL DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09DN76FC
2009 ATV SPORTSMAN 500 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09MN50AN/AX
2009 ATV SPORTSMAN 500 EFI TRACTOR DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09MN50ET
2009 ATV SPORTSMAN 800 HO EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09MN76AX/AZ
2009 ATV SPORTSMAN X2 500 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09TN50AX/AZ
2009 ATV SPORTSMAN X2 500 EFI QUAD DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09TN50EA
2009 ATV SPORTSMAN X2 800 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A09TN76AL/AX/AZ
2008 ATV SPORTSMAN TOURING 500 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08DN50AF/AS/AW/AZ
2008 ATV SPORTSMAN TOURING 500 EFI QUAD DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08DN50EA
2008 ATV SPORTSMAN TOURING 800 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08DN76AF/AG/AH/AL/AJ/AS
2008 ATV SPORTSMAN TOURING 800 EFI INTL DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08DN76FC
2008 ATV SPORTSMAN 500 EFI SCANDINAVIAN DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08MH50SS/SQ
2008 ATV SPORTSMAN 800 EFI SCANDINAVIAN DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08MH76SS/SF
2008 ATV SPORTSMAN 500 HO EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08MN50AF/AN/AQ/AR/AS/AT/AW/AX
2008 ATV SPORTSMAN 800 HO EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08MN76AF/AL/AQ/AR/AS/AT/AX
2008 ATV SPORTSMAN X2 500 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08TN50AT/AX/AZ
2008 ATV SPORTSMAN X2 500 EFI QUAD DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08TN50EA
2008 ATV SPORTSMAN X2 700 EFI DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08TN68AX/AZ
2008 ATV SPORTSMAN X2 800 EFI LE DRIVE TRAIN, FRONT GEARCASE and MOUNTING - A08TN76AA/AQ
2007 ATV SPORTSMAN X2 500 EFI GEARCASE, FRONT (ACTIVE DESCENT CONTROL) - A07TN50AF/AS/AU
2007 ATV SPORTSMAN X2 800 EFI GEARCASE, FRONT (ACTIVE DESCENT CONTROL) - A07TN76AF/AL/AU
2007 ATV SPORTSMAN 500 EFI GEARCASE, FRONT (ACTIVE DESCENT CONTROL)(If Built After 7/17/06) - A07MN50AF/AN/AT/AY
2007 ATV SPORTSMAN 800 EFI GEARCASE, FRONT (ACTIVE DESCENT CONTROL)(If Built After 7/17/06) - MN76AF/AT/AY

Like Lost cause said, you can fix it yourself for less than $200 in a few hours without any special tools.
 

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Discussion Starter #4
Thanks Guys

I got that part # and cross reference list from the dealer. I'm going to get a break down of the parts (I hope) when I pick up the machine.
 

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Discussion Starter #6
Now that the weather has supposedly broken, I have started working on this. I put in the aluminum cage from Super ATV put it in and re-assembled. As I put the cover on to the differential I am able to turn the prop shaft quite easily. Once I start getting a little torque on to the bolts the prop becomes increasingly difficult to turn to the point of needing to use a lever in order to turn it.
Also on the parts phish from polaris there is is a "clutch basket spacer" that they say to discard when replacing using their assembly of the sprague carrier. I have tried it with and without this spacer and the result is the same.
I'm open to ideas....
 

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Discussion Starter #7
latest news: I checked the thrust button and I don't think that this has ever been adjusted, pulled the screw back & pushed in the plate and button, made sure it was all moving freely.
What I did notice though was that the cage is a hair longer than the clutch housing/ ring gear ( pics attached ) I used a straight edge to make sure I was flush on the gear side, first pic. As you can see the sprague carrier extends maybe 1/32" . I am thinking that could be the issue?
Let me know what you all think.
 

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Discussion Starter #10 (Edited)
The part with no name

Sorry, I had difficulty getting the pics off of my phone and into here. The Length of the cage was NOT the problem. And the techs at Super ATV were a big help. If you are looking at the Polaris parts phishe, the very first part going inside of the diff housing is a bushing maybe 5/8th" wide, and a little more than 3" in diameter and it has no part number. Mine was sticking out or was not flush with the housing which seems to have been causing the binding. Just a few loving taps using a block and everything went together easily. A big key in this project is don't force any of this.
I'm waiting on new seals but hopefully this is the end of my story here.
Thanks for all the help
 
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