RZR Front Differential Rebuild

This instructable will walk you through rebuilding a Polaris RZR front differential.  The process only takes about 15 minutes with the right tools and if you do everything in the right order. 

The new sprague should slide right into the existing ring gear without a lot of force.  Make sure the bearings and ring are in the ring gear and drop it in the differential casing with the teeth of the gear facing down.

The cover plate should have a rust washer, a small red colored tab that fits over a square with a circular metal insert on the outside of the cover plate.

The armature plate should slip on the back of the ring gear with the metal teeth fitting in the grooves in the back of the ring gear.

Gently drop the cover over the ring gear until there is no gap between the two pieces and make sure that the gear spins freely once installed.

The bolts should go into the differential casing smoothly.  Be sure not to strip out the inside of the bolt holes.  Once the bolts are tightened, the gear should still move freely when spun.