On this page we will go through the procedure to remove, disassemble, inspect, repair and reinstall a gearbox in a 2004 Polaris Ranger 4x4. Check local laws before riding on trails. Never engage in stunt driving, and avoid excessive speeds and sharp turns. This is the internal problem caused by the shift mechanism. Interact directly with top Vendors in the Industry, find exclusive discounts and specials and participate in weekly giveaways! Always use seat belts and cab nets or doors as equipped.
I may do my own someday when I tear down my next trans. The driven pawl on the high gear was stipped to a ramp shape causing it to kick out of gear and grind, the thrust face of the pawl should be tapered slightly toward the gear for positive engagement. The bolt between the gearbox and engine was removed too at this time. If you have any doubt as to your ability to perform any of the procedures outlined in this service manual, contact an authorized Polaris dealer for service. Call 800-342-3764 for additional information. All riders should always wear helmets, eye protection, and protective clothing.
The shift linkage was adjusted with the two nuts on the cable housing, after that did not work the nuts were loosened and the housing was rotated 90 degrees to remove it from the mounting bracket. This will be rectified by cleaning and resealing the shift cover. Polaris uses Peer brand bearings in their transmissions, and they are Chinese made. After adjusting the shift linkage the grinding still occurred. Because I know a machine is only as strong as its weakest component. Then the gearbox was moved forward to release the rear U joint from the output shaft.
The bearings themselves I buy from my local auto parts store, which just happens to be a Car Quest. The front driveshaft was sprayed with penitrating oil to aid in removal The gearbox was moved back toward the rear to remove the front U joint from the output shaft. You must read the service manual and be familiar with the service procedures before starting the work. Send us your worn or broken Polaris Ranger 500 Engine for a complete professional rebuild. Warning: Polaris off-road vehicles can be hazardous to operate and are not intended for on-road use.
This price does not include parts. My dealer just pulled another one apart last month, and finally agreed with me that polaris has a quality issue with the bearings they're using in their transmissions. When I go into them, I change the seal for the transmission input shaft from the secondary clutch. The ranger came in to our shop with the high gear grinding and would not engage, our first step is to adjust the linkage as that can cause the problem. Their bearings just aren't cutting the mustard. The failure to follow correct procedures and use correct tools could result in serious injury or death.
Procedures indicated to be performed by dealers only could void your warranty if performed incorrectly. The next step is to remove the gearbox for internal inspection. If you haven't registered yet, what are you waiting for? The 4 2 Phillips screws were removed using a 2 impact screw driver to avoid stripping them. Consumer Warning In order for work to be performed safely and correctly many parts replacement procedures and repair procedures must be done by trained Polaris service technicians in a properly equipped shop. Certain procedures require the use of special tools that are not available to the general public and your dealer will have to perform these procedures for you as necessary. Passengers, if permitted, must be at least 12 years old. There are three parts to this video, so be sure not to miss the next ones that will usually follow after the first.
That's why I got a Polaris and that's why I maintain it with Polaris Engineered Parts. Why do I choose Polaris Engineered Parts? I haven't crossed them over to generic seals yet. Then the clip holding the cable to the shift lever was removed and the cable moved to the side. I need every piece to fit together perfectly the way it was engineered to. .
© 2019 Polaris Industries Inc. This was the cause of the internal faiure, moisture got in to the internal shift mechanism causing the detent to rust and fail to firmly hold gear position. This is also known as the Torque converter housing. All riders should take a safety training course. This includes Tear down inspection with failure analysis and measuring of all critical components and assembly. The gearbox was twisted slightly to exit the right side of the Ranger The gearbox was drained then sealed off with a peice of hose and pressure washed to remove all the dirt and grease from the outside, this must be done just before dissasembly in case water gets in. The hose clamps on the belt housing air outlet the top of the belt housing cover were loosened in preperation of removal of the cover.