Polaris Ranger 800 Crew Gearcase Fluids Change

Changing the gearcase fluid in your Polaris UTV’s front diff and transmission housing is just as important a maintenance task as changing the engine oil.

Follow the steps below and watch the video above to change a Polaris Ranger 800 Crew’s gearcase fluid. 

Tools and Supplies Needed – Polaris Ranger Crew Gearcase Oil Change

Tools

  • Ratchet and universal joint
  • Long extension bar
  • 8mm socket
  • 8mm Allen
  • Torque wrench
  • Drain pan

NOTE: The steps for changing the front diff and transmission fluids on a Polaris Ranger 800 Crew are the same or similar for most Polaris side-by-sides.

How to Change Polaris Ranger 800 Crew Front Diff Oil

Step 1. Use an extension bar and a universal joint to access and remove the 8mm fill screw on the upper left side of the front differential. This allows the diff to vent and drain properly.

Polaris Ranger Crew 800 parts diagram

PRO TIP: If the universal joint swivels too much, wrap a couple of turns of electrical tape around it to make it easier to maneuver into position.

Step 2. Position a drain pan underneath the front differential, and remove the 8mm drain screw from the bottom of the diff.

Polaris Ranger Crew 800 front diff oil change

PRO TIP: To ensure the Allen seats properly so it doesn’t strip the heads, remove any debris from the fill screw and drain screw heads before loosening them. 

Step 3. Allow the diff oil to drain out, then clean the drain screw, reinstall it into the diff and torque it to 10 foot-pounds.

Step 4. Attach an oil jug pump to a quart bottle of demand drive fluid, then attach a length of 5/16th hose to the pump.

Polaris Ranger Crew front differential oil change

Step 5. Place the hose into the front differential fill hole, and slowly pump the demand drive fluid into the diff. Continue to fill the diff until the fluid reaches the fill hole and begins to spill out.

Step 6. Reinstall the front diff fill screw and torque it to 10 foot-pounds.

Polaris Ranger UTV front diff fluid change

Watch the clip below to see the front diff oil change segment of our Polaris Ranger 800 Crew gearcase oil video.

How to Change Polaris Ranger 800 Crew Rear Transmission Fluid

Step 7. Use an extension bar and a universal joint to access and remove the 8mm fill screw in the right side of the rear transmission housing. This allows the diff to vent and drain properly.

Polaris Crew 800 transmission parts diagram

PRO TIP: If the universal joint swivels too much, wrap a couple of turns of electrical tape around it to make it easier to maneuver into position.

Step 8. Position a drain pan under the transmission housing, and remove the 8mm drain screw from the bottom of the housing.

Polaris Ranger Crew 800 transmission fluid fill

PRO TIP: To ensure the Allen seats properly so it doesn’t strip the heads, remove any debris from the fill screw and drain screw heads before loosening them. 

Step 9. Allow the transmission fluid to drain out, then clean the drain screw, reinstall it into the transmission housing and torque it to 14 foot-pounds.

Step 10. Attach an oil jug pump to a quart bottle of AGL gearcase lube, and attach a length of 5/16th hose to the pump.

Polaris Ranger UTV transmission fluid change

Step 11. Place the hose into the rear transmission fill hole and slowly pump the AGL fluid into the transmission. Continue to fill the transmission until the fluid reaches the fill hole and begins to spill out.

Polaris Ranger Crew 800 transmission oil change

Step 12. Reinstall the rear transmission fill screw, then torque it to 14 foot-pounds and you’re done.

Watch the clip below to see the transmission oil change segment of our Polaris Ranger 800 Crew gearcase oil video.

 

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