HOW-TO: Upgrade your RZR transmission

Rock crawling places extreme stresses on a UTV transmission, clutch and drivetrain, and we’ve seen a couple of High Lifter Edition RZR XP 1000s converted to rock crawlers at rallies in Utah. High Lifter Edition XP 1000s (’15–’16) and XP 4s (’16) have lower transmission gearing and stronger double-row reverse chains for running larger mud tires, so rock crawlers would also benefit from High Lifter gearing. We’ve also seen RCV Performance axles on more UTVs at the last two King of the Hammers, with Blake Van do Loo using them to win this year’s KOH. RCV also makes a heavy-duty front output shaft that strengthens the drivetrain on older (up to ’14) RZRs and pretty much all ’15–’16 RZRs, Rangers and Aces.

While sitting around camp at Moab’s Rally on the Rocks, we were bench racing about the day’s ride and how larger tires would make rock-crawling easier, but the taller tires would place even more stress on the XP1K transmission and driveline. Since we had upgraded our front diff to High Lifter Edition parts (January 2016), why not do the same to the transmission? Triple S Polaris of Cedar City offered to do the swap and also suggested we’d be ahead of the game if we also installed RCV’s 300M Ultimate output shaft. We decided to go big with our shaft. We decided to go big with our 2015 Voodoo Blue XP 1000 and took 2015 Voodoo Blue XP 1000 and took it to Triple S for the conversions. I also it to Triple S for the conversions. I also picked RCV’s Ultimate output shaft to picked RCV’s Ultimate output shaft to complement the High Lifter upgrade complement the High Lifter upgrade parts and move any potential problems parts and move any potential problems to outside of the transmission. to outside of the transmission.

HIGH LIFTER TRANSMISSION UPGRADES
Removing and splitting the RZR transmission is akin to an engine rebuild, so it’s beyond many people’s mechanical skills. If you want to simply switch to the High Lifter Edition transmission outright, the cost would be $2061, plus $25 for shipping. We had Triple S do it and saved $644.68; had we done the labor ourselves, we would’ve saved another $472.50 in labor.

Triple S removed the muffler and jacked up the XP to get extra droop in the axles and access for removing the CVT. Remove the transmission’s fill and drain plugs and dispose of the oil. Sam McIntyre of Triple S has a trick for cutting down on transmission-removal time. He unbolts the transmission from the engine and frame, uses the extra suspension droop to wiggle the axles (rearward) and forward shaft from the assembly, and he then extracts the assembly from the car. He then split the cases.

The High Lifter Edition larger, doublewide, reverse chain requires changing two shafts, which means you have to press the bearings off of the old shafts and press them onto the reverse (part #3235380) and input (part #3235631) shafts. The OEM reverse shaft has a 29-tooth sprocket, while the High Lifter gear is a 25-tooth. The OEM Stage 3 gear is a 44-tooth, while the High Lifter gear is a 48-tooth.

The parts total from RCV was $249 (RCV #D7780), while the Polaris total was $968.82. Here is what you’ll need.

With the new gears, shafts, reverse chain and seals installed, the transmission halves went back together and the unit was wedged back into the car with the new RCV Ultimate output shaft. The CVT inner cover, clutches, belt and outer cover were next, then Sam hooked up the cooling duct. Then 44 ounces of AGL Gearcase lube and transmission fluid (#2878068) went into the fill hole, and the plug was torqued to 12 foot-pounds.

We loaded up and took the XP1K to the Dixie National Forest for testing. I found the car easier to drive slow and pick my way through rocks, trees and tight trail. The gear swap was pricey, but it works well, and we’re looking forward to trying 32-inch tires with confidence that the tougher transmission can take the extra stress.

HIGH LIFTER PARTS LIST
3235380.Reverse shaft/25T ……….$229.99
3235631.Input shaft 42T/20T/25T .$159.99
3235381.Stage 3 gear/48T ………..$109.99
3235632.6-Face sprocket/48T ……$199.99
3235633.Silent reverse chain ………$199.99
3235052.Triple-lip 2 seal (40x70x7) .$14.44
3235658.High-temp 1 seal (25x80x10) $39.99

Here is the OEM assembly (top) with the bearings, gears, sprocket, shifters and chain installed, and the High Lifter shafts, gear and reverse chain. A gear puller and press will be needed to remove the OEM bearings.
Here is the OEM assembly (top) with the bearings, gears, sprocket, shifters and chain installed, and the High Lifter shafts, gear and reverse chain. A gear puller and press will be needed to remove the OEM bearings.
Install the OEM shift clutches and 48-tooth High Lifter gear on the Install the OEM shift clutches and 48-tooth High Lifter gear on the new shafts and press on the bearings.
Install the OEM shift clutches and 48-tooth High Lifter gear on the Install the OEM shift clutches and 48-tooth High Lifter gear on the new shafts and press on the bearings.
Do the same for the pinion output shaft; press off the bearing and swap the OEM 44-tooth gear for the 48-tooth High Lifter gear.
Do the same for the pinion output shaft; press off the bearing and swap the OEM 44-tooth gear for the 48-tooth High Lifter gear.
Here’s the RCV Ultimate output shaft (right) with heavy-duty retaining ring and the OEM part. Remove the OEM retaining ring, washer, 13-tooth snorkel gear, snorkel tube, bearing, shim, external retaining rings and shims, and place them on the RCV shaft.
Here’s the RCV Ultimate output shaft (right) with heavy-duty retaining ring and the OEM part. Remove the OEM retaining ring, washer, 13-tooth snorkel gear, snorkel tube, bearing, shim, external retaining rings and shims, and place them on the RCV shaft.
Here’s the High Lifter transmission with shift-fork assembly, shift drum, idler shaft and output gear installed.
Here’s the High Lifter transmission with shift-fork assembly, shift drum, idler shaft and output gear installed.
Plug the new RCV output assembly into the case and tap home the new seal. With the left-hand case complete, tap the new seal into the right-hand case and bolt the two halves together.
Plug the new RCV output assembly into the case and tap home the new seal. With the left-hand case complete, tap the new seal into the right-hand case and bolt the two halves together.
Wrestle the transmission into the frame, plugging the new RCV output Wrestle the transmission into the frame, plugging the new RCV output shaft into the front drive shaft and axles into their holes. Bolt it into shaft into the front drive shaft and axles into their holes. Bolt it into the frame and brackets and reconnect the shift cable.
Wrestle the transmission into the frame, plugging the new RCV output Wrestle the transmission into the frame, plugging the new RCV output shaft into the front drive shaft and axles into their holes. Bolt it into shaft into the front drive shaft and axles into their holes. Bolt it into the frame and brackets and reconnect the shift cable.
Reconnect the CVT intake ducting and inner cover; replace the primary, secondary clutches and belt; make sure the cover seal and shaft washers are in place; and bolt on the outer cover and intake duct.
Reconnect the CVT intake ducting and inner cover; replace the primary, secondary clutches and belt; make sure the cover seal and shaft washers are in place; and bolt on the outer cover and intake duct.
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