Transfercase issue

[krew06]

My 2009 polaris rzr 800 has a hole in the bottom of my transfer case. Do I have to pull my motor out to replace my transfer case or is there another way? I am a rookie at this whole thing so any help would be greatly appreciated! And/or if you have one for sale that would be great too.

[RZRluvr]

Do you have any pics? And how big is the hole? If it's not too big it can be welded up:D

[megadesertdiesel]

Its bolted to the motor with a pita bracket deep in the middle of the two. The rear diff is also bolted in there.

It will be easier to remove the clutches, then remove the 3 motor mounts and pull it all out as one unit then remove the trans off the motor and rear differential.

If you did not damage the internals, i would drain the oil, disassemble the trans, boil the oil out of the crack, then have a welder weld it up and smooth the inside if the bead is in the way.

It would not hurt to plate the bottom side with 1/4" aluminum so you dont break it again.

[onerich]

IS the hole in the front of case or the back half?

maybe you would be able to weld it in place (but not sure ) , but it would need to be drained .

And then there is allways JB WELD some people swear by it .

[krew06]

This is all useful information. I will take pictures of the hole and put them up. The hole is towards the front. I also do not think there are any issues with the guts of the transfer case since there is no difficulty in putting into gear. Anymore ideas would be greatly appreciated.

[krew06]

Also yes 1/4'' aluminum will definitely be put on once everything gets repaired.

[RZRluvr]

I know you have figured this out by now but get a good skid plate. Stay away from aluminum cause it will bend and tear. Factory UTV and Fiber Skins both make awesome skids. FUTV is UHMW and FS uses a carbon fiber like material. I run the 1/2" FUTV and I also just installed the Holz 1/4" motor lift plates for some added clearance:D I have 3500 hard miles on my skid and have beat the hell out of it and not a mark on the bottom of the motor, trans or transfer:D Good luck and Happy Holidays:D

[krew06]

Here is the picture

[onerich]

Wow , now thats a hole. I don;t think that can be repaired but I could be wrong. A rear case runs around $280.00 and a front runs around $190.00 and that just the case's . You might look around for a used one , pending on your wallet , good luck

[speedyangie]

Do you have all the pieces? If yes, we can definitely try to fix it. If you check my post - "Help! Rock damage" you can see what happened to ours.