Dear Sarge,

I have a high mileage RZR Turbo. I recently had it in for service where the Dealer replaced the right front drive shaft due to it being worn. Ever since then, if the conditions are right, that new drive shaft will pop out of the differential. I can pop it back in but this has happened 3 times now and the dealer’s service department claims that the drive shaft was installed correctly. I have kept replacing the Maxxis Bighorn tires because I like them and have also had the suspension rebuilt by Shock Therapy with their Stage 1 RIS valving and their Level 2 spring kit. None of these mods should have anything to do with my drive shaft problem. I am at a loss as to what to do. Everybody that I have talked to says the drive shaft was either not installed correctly or the retaining clip was reused from the old drive shaft. So Sarge, what do you think is going on here and who do I believe?

Tom Findley

Green River, Wyoming

Private Fiddle, you may not want to hear this, but… most likely your Dealer’s Motor Pool did indeed install the drive shaft correctly and no, they would never reuse the retaining clip! What they DID do wrong was to over grease the shaft, the main thing to avoid for keeping axles from exiting the differential! When there is too much grease in the differential from over greasing the axle splines, this excess grease can cause the axle to pop out under load. I suggest you pull your axle. Clean out all the excess grease from the differential and the axle splines. Put a small amount of fresh grease on the splines and none on the end of the shaft. Excess grease on the splines is wiped off as the axle is inserted but there is no place for the grease on the end of the axle to go. So it builds up and prevents complete locking in of the axle. With the excess grease removed, your axle should pop in securely and not pop back out under load. Assuming this fix works (and I believe it will), then I suggest you double time it down to the local Motor Pool and explain their failure to follow procedure to them. And then Boot, you are to consider changing your MOS to 3521! Dismissed!


Several issues can prevent axles from seating properly in the differential, causing the axle to pop out under torque loads, such as when climbing challenging obstacles, or heavy cornering loads. Dirt, excess grease, a weak retaining clip or a deformed or damaged differential housing (often from axles popping out) can keep the axle from seating securely. Be sure the axle doesn’t have excess greas on the end and be sure the retaining clip groove is perfectly clean before seating the axle.

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