Can Am Outlander Rear Differential Rebuild Kit

Hear that? That high-pitched whine from the back of your rig that gets louder as you speed up. Or maybe it’s a clunk when you get on or off the gas. You know deep down what it means, and you agree it’s a sound that makes any off-roader’s stomach drop: your rear differential is on its way out.

We promise you’re not alone, and it doesn’t have to mean a four-figure repair bill at the dealership. With the right parts, a bit of patience, and a solid game plan, you can tackle this job in your own garage.

This guide will walk you through everything. We’ll cover how to spot a failing diff, what to look for in a can am outlander rear differential rebuild kit, a step-by-step process for the rebuild, and pro tips to make sure your hard work lasts for years of trail-shredding fun.

Is Your Outlander’s Rear Differential Crying for Help? Telltale Signs

Before you start tearing things apart, you need to be sure the differential is the culprit. A failing rear diff has a few classic symptoms that are hard to ignore once you know what to listen and feel for.

These are some of the most common problems with can am outlander rear differential rebuild kit candidates. If you’re experiencing these, it’s time to pay attention.

Whining or Howling Noises: This is the number one sign. The noise will change pitch with your speed, not your engine RPM. It’s often caused by worn-out bearings or improperly meshed gears.
Grinding or Rumbling: A more severe noise that can indicate heavily damaged bearings or chipped gear teeth. You might feel this as a vibration through the seat.
Clunking on Acceleration/Deceleration: If you feel a “thud” or hear a “clunk” when you transition from on-throttle to off-throttle (or vice versa), it could be excessive backlash in the gears.
Leaking Fluid: Puddles of thick, pungent gear oil under your machine are a dead giveaway. This points to failing axle seals or a bad pinion seal.
Vibrations: A vibration that gets worse with speed can be a sign of a failing pinion bearing or an out-of-balance driveshaft connected to a worn-out pinion yoke.

The Big Benefits of a Can-Am Outlander Rear Differential Rebuild Kit

So, you’ve confirmed your diff is toast. Why go the rebuild route instead of buying a whole new unit? There are some serious advantages to grabbing a wrench and doing it yourself.

Understanding the benefits of can am outlander rear differential rebuild kit use goes beyond just the final product; it’s about the value you get from the process.

Massive Cost Savings: This is the big one. A complete rear differential assembly can cost a fortune. A rebuild kit, even a high-quality one, is a fraction of that price. The money you save on labor is the cherry on top.
Performance Restoration: A rebuild replaces all the wear-and-tear items—bearings, seals, and shims. This brings tolerances back to factory spec, resulting in a quieter, smoother, and more reliable drivetrain.
Upgrade Opportunity: Many aftermarket kits from reputable brands feature bearings and seals that are more robust than the original OEM parts. You’re not just fixing it; you’re making it stronger.
Invaluable Experience: There’s no better way to understand your machine than by working on it. Successfully rebuilding a differential is a major confidence booster and adds a serious skill to your DIY mechanic resume.

Choosing the Right Rebuild Kit: A Quick Buyer’s Guide

Not all kits are created equal. A quick search for a “can am outlander rear differential rebuild kit” will give you a ton of options. Knowing what to look for ensures you only have to do this job once.

What’s Inside the Box?

A comprehensive kit should include all the essential components. At a minimum, look for:

All Bearings: This includes the two carrier bearings, the inner and outer pinion bearings, and often the axle bearings.
All Seals: You’ll need two axle seals and one pinion seal.
Pinion Nut and Crush Sleeve: These are one-time-use items. Never, ever reuse the old ones. A quality kit will always include new ones.
Shims: While you may reuse some of your old shims to set the initial backlash, a good kit may include a small assortment to help you dial it in perfectly.

Sustainable and Eco-Friendly Rebuild Kit Considerations

Thinking green in the garage is a great habit. A key part of a sustainable can am outlander rear differential rebuild kit approach is the act of rebuilding itself. You’re saving a large, heavy chunk of metal from the scrap heap.

Furthermore, an eco-friendly can am outlander rear differential rebuild kit practice involves responsible disposal. Make sure you take your old gear oil and metal parts to a proper recycling facility. It keeps our trails and environment clean for everyone.

How to Rebuild Your Can-Am Outlander Rear Differential: A Step-by-Step Guide

Alright, time to get your hands dirty. This is a detailed overview. Crucial disclaimer: This is an advanced mechanical job. Setting gear mesh and bearing preload requires precision tools and patience. Always have your specific model’s factory service manual handy for exact torque specs and measurements.

Step 1: Preparation and Removal

First, get your workspace and tools ready. You’ll need a solid set of tools, including a torque wrench, a gear puller, and ideally, a hydraulic shop press.

Safely lift your Outlander and secure it on heavy-duty jack stands. Safety is non-negotiable.
Remove the rear wheels, hubs, and brake calipers.
Carefully pull the axles out of the differential. Have a drain pan ready for any fluid that spills.
Disconnect the rear driveshaft from the pinion yoke.
Place a jack under the differential for support, then unbolt it from the frame and lower it out of the machine.

Step 2: Disassembly on the Workbench

A clean workbench is a happy workbench. Before you open the differential, clean the entire exterior to prevent dirt from getting inside.

Use a punch or paint marker to mark the bearing caps and their orientation. They must go back in the same place and same way.
Remove the differential cover and drain any remaining fluid. Inspect the oil for metal shavings—a silver paste is normal wear, but large chunks are a bad sign.
Remove the bearing caps and carefully pry out the carrier assembly (the part holding the large ring gear). Keep track of which shims came from which side.
Use a special yoke-holding tool and a large breaker bar to remove the pinion nut. Then, pull the yoke off the pinion shaft.
Tap the pinion gear out from the inside of the housing.
Now, use a bearing puller and press to remove all the old bearings and seals from the housing and the carrier.

Step 3: Cleaning, Inspection, and Installation

This is where attention to detail pays off. Every part must be spotless before reassembly.

Clean the inside of the housing, the carrier, and the gears with brake cleaner and a lint-free rag.
Inspect the ring and pinion gears carefully. Look for any chipped, cracked, or severely worn teeth. If you find significant damage, a rebuild kit won’t fix it. You’ll need a new gear set or a complete differential assembly.
Using a press or proper bearing drivers, install the new bearing races into the housing. Ensure they are seated completely.
Press the new carrier bearings onto the carrier and the new pinion bearings onto the pinion shaft.

Step 4: Setting Preload and Backlash (The Critical Part)

This is the most technical part of the entire job and where our can am outlander rear differential rebuild kit guide becomes most important. Get this wrong, and your newly rebuilt diff will fail prematurely.

Pinion Depth and Preload: Install the pinion with its new crush sleeve. As you tighten the new pinion nut, the sleeve collapses, setting the preload (the rotational resistance) on the bearings. Use an inch-pound beam-style torque wrench to measure this resistance. You’re aiming for a very specific spec from your service manual (e.g., 15-25 in-lbs).
Backlash: Reinstall the carrier with its original shims. Mount a dial indicator to the housing with the tip touching a tooth on the ring gear. Gently rock the ring gear back and forth. The amount of play is the backlash. You’ll need to move shims from one side of the carrier to the other to get this within the factory spec (e.g., 0.008″-0.012″).
Contact Pattern: Use gear marking compound to paint a few teeth on the ring gear. Rotate the assembly several times and look at the pattern left on the teeth. The manual will show you what a good pattern looks like. Adjust pinion depth (using shims behind the inner pinion race) and backlash until the pattern is centered on the tooth.

Pro Tips and Best Practices for a Flawless Rebuild

Want to do the job like a seasoned pro? Follow these can am outlander rear differential rebuild kit best practices.

Take Photos: Before and during disassembly, take pictures with your phone. They are free and can be a lifesaver when you can’t remember how something went together.
Work Clean: Any piece of dirt or grit that gets into a new bearing can destroy it in short order. Keep your parts, tools, and hands clean.
Freeze and Heat: To make installing bearing races easier, you can put the races in the freezer for an hour and gently warm the housing with a heat gun. The temperature difference will make them slide in with much less force.
Don’t Force It: If something isn’t fitting, stop and figure out why. Using a bigger hammer is almost never the right answer.
Trust The Manual: Your factory service manual is the bible for this job. The specs in it are not suggestions.

Post-Rebuild Care and Maintenance Guide

You did it! But the job isn’t quite over. Proper care right after the rebuild is key to longevity. This is your essential can am outlander rear differential rebuild kit care guide.

First, perform a break-in period. For the first 50-100 miles, take it easy. Avoid full-throttle launches, heavy towing, or deep mud. This allows the new gears and bearings to seat properly.

After that break-in period, change the gear oil. This will flush out any microscopic metal particles that shed during the initial meshing process. Refill with high-quality synthetic gear oil as specified in your owner’s manual, and you’ll be set for thousands of miles of trouble-free riding.

Frequently Asked Questions About Can-Am Outlander Rear Diff Rebuilds

How long does a rear differential rebuild take?

For a skilled DIYer with the right tools, plan for a full day (6-10 hours). If it’s your first time, it’s smart to set aside a full weekend to avoid rushing.

What’s the hardest part of the job?

Without a doubt, correctly setting the pinion preload, carrier preload, and gear backlash. This step requires precision tools and a deep understanding of the process. Rushing this step will guarantee a noisy and short-lived differential.

Can I rebuild the differential without special tools like a press?

While technically possible using sockets, hammers, and pullers, it is highly discouraged. The risk of damaging a new bearing or race by not pressing it in perfectly straight is extremely high. Renting or borrowing a shop press is the best investment you can make for this job.

What kind of gear oil should I use after the rebuild?

Always check your service manual for the exact specification. Most modern Can-Am Outlanders require a high-quality 75W-90 or 75W-140 synthetic hypoid gear oil.

When should I just replace the whole differential instead of rebuilding?

If your inspection reveals chipped, cracked, or heavily pitted ring and pinion gear teeth, a simple rebuild won’t solve the problem. In this case, your options are to buy a new gear set (which adds complexity) or a complete, new differential assembly.

Rebuilding your Outlander’s rear differential is a challenging but incredibly rewarding project. It saves you a pile of cash and gives you the ultimate confidence in your machine because you know it was put together right. Take your time, be meticulous, and follow the specs.

Now get those tools ready, put on some good music, and get that rig back on the trail where it belongs. Happy wrenching!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.