Polaris RZR Front Differential Rebuild Kit with Roll Cage

When the AWD on a Polaris RZR 800 or 900, Ranger 900 or ACE engages late, grabs and lets go, or never comes in at all - often with a click or grind from the front under throttle - the problem is almost always inside the front gearcase. This kit replaces the parts that wear out in that case: the roll cage (sprague) with its clips, the armature plate, the output hub assembly, and a complete front differential bearing and seal set. It cross-references Polaris numbers 3235263, 3234466, 3234907, 3235261, 3235262, 3234410, 3234407, 3235174, 3235171, 3234393 and 3235169.

What the roll cage and armature plate do in a Polaris front gearcase

The Polaris front drive is an on-demand system, not a locked axle. The ring gear always turns with the driveshaft, but power only reaches the front wheels when a cage full of steel rollers wedges between the ring gear and the output hubs. To make that happen, an electric coil in the case pulls the armature plate against it; the drag on the plate rotates the roll cage just enough to set the rollers. When the front and rear wheels are turning at close to the same speed, the fronts overrun the hubs, the rollers are pushed back out, and the front lets go. If the cage is cracked, the rollers are worn or the armature plate is glazed, the coil can no longer drag the cage into lockup, and you get weak or no AWD.

Symptoms of a worn roll cage or armature plate

• AWD engages late or only after a lot of rear wheel spin
• Front grabs and releases, with a ratcheting click under throttle
• No AWD at all even though the dash light comes on
• Grinding or whine from the front case, or milky front fluid
• Oil weeping from an output seal

How to confirm before you split the case

Start with the easy checks. Make sure the AWD switch, fuse and coil connector are good, and check the coil resistance against your service manual. Pull the drain plug: water-milky fluid means a seal let the creek in and the bearings are next, and chunks of plastic or metal on the magnet point to a broken cage. If the coil checks good and the fluid is clean but the front still will not engage, the cage, rollers or armature plate are worn. If you find chipped teeth on the ring gear or pinion when the case is open, that is a separate job for the front differential ring and pinion gear set.

Fitment

Listed for the RZR S 800 and RZR 4 800 2011-2014, RZR 900 2011-2016 (not the RZR 900 4 EPS), RZR 900 S 2017 built before 8/29/16, Ranger 570 Full-Size and Crew 2015, Ranger 900 XP 2013-2016, Ranger 900 Crew 2014-2015, Ranger Diesel 900 and Crew 2011-2014, and the ACE 325 and ACE 570 2016. Polaris changed front gearcases more than once inside those years, and some cases use a different armature plate tooth count, so compare the number cast or tagged on your gearcase with the numbers above, or send us the model, year and VIN. More drivetrain parts are on the hard parts page.

Install notes

• Pull the front gearcase, drain it, and split the case on the bench.
• Remove the output hubs and old roll cage; clean every roller pocket and check the coil face.
• Press in the new bearings and seals squarely, then install the new output hub, roll cage with fresh clips and armature plate.
• Close the case with a clean sealing surface and torque to the service manual spec.
• Refill with Polaris Demand Drive fluid to the bottom thread of the fill plug hole, and do not overfill.
• Test on loose ground that the front engages and releases before trail use.

If the drivetrain is apart for a belt or clutch service at the same time, a Polaris clutch removal and spider tool kit makes the primary clutch job safe. A fluid fill pump makes topping off the front case through the side fill plug much easier.

Why does my RZR have no front drive even though the AWD light is on?

The light only tells you the switch is on. If the coil is good, the usual cause is a worn roll cage, worn rollers or a glazed armature plate that can no longer drag the cage into lockup - exactly the parts in this kit.

Does this kit fit the RZR 900 4 EPS?

No. The listing excludes the RZR 900 4 EPS. It covers the 2011-2016 RZR 900, 2011-2014 RZR 800, the Ranger 900 XP and Crew, Ranger Diesel 900, 2015 Ranger 570 Full-Size and 2016 ACE 325 and 570.

What fluid goes in the front differential?

Polaris Demand Drive fluid. Fill to the bottom thread of the fill plug hole on the right side of the case and do not overfill. Follow the periodic maintenance chart, and change it sooner after water crossings or hard, constant AWD use.

Do I need to replace the ring and pinion too?

Only if the teeth are chipped, pitted or worn. Inspect them when the case is split; most no-AWD complaints are solved with the cage, armature plate, hub, bearings and seals in this kit.

How do I know which gearcase I have?

Polaris changed front cases within these years. Check the part number on your gearcase or send us your model, year and VIN, and we will confirm the kit matches.