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Front Differential
Many Polaris RZR 4 owners believe that the front differential cannot handle large aftermarket tires, but this is a common misconception. A stock RZR 4 front differential can handle 30”, 32”, and even 33” tires without any issues. In most cases, if there are issues, it is not the fault of the tires. If there is oil leaking from the front differential, it is recommended to inspect the seals when disassembling it. Rebuilding the front diff on an RZR 4 is not too difficult, but it is important to take pictures to ensure it all goes back together correctly. Replacing the factory bolts with longer ones is also a good idea. If you want a bulkier front differential, a turbo differential or RS1 differential with an adapter plate can be added. If you are not satisfied with the performance or durability of your stock RZR front differential, there are many options available.
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In addition to installing aftermarket differentials or diffs from other RZR models in your machine, in many cases, a faulty component or constituent differential part is the culprit. Replacing the front differential Sprague with an aluminum one from a company like SATV, putting in new differential bearings, swapping out the diff seals, and exchanging the armature plate for a new one are all ways to save an old differential from the junkyard and extend its life -- and thereby saving you money. Regardless if you do the work or you take your rig to a dealer, it is important to use Locktite when installing the four front differential bolts that attach the diff to the cage of the RZR. And because most mechanics use air drivers, it’s not uncommon for them to strip the bolt threads when working on the front diff. You can check this by looking at the first half of the threads. If they appear kind of melted, they are likely stripped. Poor dealer service is always a challenge. However, if they don’t already, make sure your dealer records the mileage, hours, and other applicable stats on your RZR when you take it in to get work done. That way, you have a defensible argument should there be issues in the future.
