Can Am Outlander Rear Differential Replacement

Hear that dreaded grinding or whining from the back of your rig? Feel a clunk when you get on the gas? If you’re nodding along, you’ve come to the right place. A failing rear differential on a Can-Am Outlander can sideline your machine and turn a weekend of fun into a weekend of frustration. But don’t start dialing the dealership just yet. We promise that with the right tools, a bit of patience, and this expert guide, you can tackle this job yourself. This article will walk you through everything from diagnosing the problem to the final test ride, providing a complete can am outlander rear differential replacement guide that will get you back on the trail with confidence.

Is Your Rear Differential Toast? Signs It’s Time for a Replacement

Before you start turning wrenches, it’s crucial to confirm the rear differential is actually the culprit. Misdiagnosing the issue is a costly and time-consuming mistake. The rear differential is a tough component, but the extreme torque and harsh conditions of off-roading can take their toll.

Here are the classic tell-tale signs that your Can-Am’s rear end needs attention.

Common Symptoms of a Failing Rear Differential

Grinding or Whining Noises: This is the most common symptom. The sound often changes with speed and can be more noticeable during turns. It usually points to worn-out gears or bad bearings inside the differential case.
Loud Clunking or Banging: A loud “clunk” when you accelerate, decelerate, or shift into gear often indicates excessive backlash (too much space) between the ring and pinion gears or even broken teeth.
Fluid Leaks: Puddles of thick, dark gear oil under the rear of your ATV are a dead giveaway. This is usually caused by a failing pinion seal or axle seals. Running a differential low on fluid is a guaranteed way to destroy it.
Vibrations: A vibration that gets worse with speed can sometimes be traced back to a failing differential. This is often due to worn-out bearings or a pinion gear that’s out of balance.
One-Wheel-Peel: If you notice only one rear wheel spinning in situations where both should have traction, your differential might not be locking or transferring power correctly.

To confirm, safely lift the rear of your ATV on jack stands. With the machine in neutral, try to spin the rear wheels by hand and wiggle them side-to-side. Any excessive play, grinding sounds, or roughness is a strong indicator that it’s time for a can am outlander rear differential replacement.

Gearing Up: Essential Tools & Parts for the Job

Walking back and forth to the toolbox is no fun. A successful replacement starts with having everything you need laid out and ready to go. This isn’t a job for a basic socket set; you’ll need a few specialty items to do it right and safely.

The Must-Have Tool List

A robust set of jack stands and a floor jack
Metric socket set (deep and shallow) and a ratchet set
A set of metric wrenches
A high-quality torque wrench (this is non-negotiable for safety)
Breaker bar for stubborn bolts
Pry bars and a dead-blow hammer
Drain pan for old gear oil
Brake cleaner and shop towels for cleanup
Threadlocker (Blue Loctite is usually a good choice)
Anti-seize compound for reassembly

Parts You’ll Need

The New Differential: You can choose an OEM (Original Equipment Manufacturer) unit or a heavy-duty aftermarket one. We’ll discuss the pros and cons later.
Fresh Gear Oil: Check your owner’s manual for the correct type and viscosity. Don’t cheap out here! We recommend a full synthetic 75W-90 or 75W-140 gear oil for most applications.
New Cotter Pins: Always use new cotter pins for axle nuts and tie rods.
Optional but Recommended: Consider replacing the axle seals while you’re in there, even if they aren’t leaking yet. It’s cheap insurance.

The Ultimate Can Am Outlander Rear Differential Replacement Guide

Alright, let’s get down to business. This is the core of our how to can am outlander rear differential replacement section. Work methodically, stay organized, and prioritize safety above all else. Remember to take photos as you go—they can be a lifesaver during reassembly.

Step 1: Preparation and Safety First

Park your Outlander on a flat, level surface. A concrete garage floor is ideal.
Before lifting, use a breaker bar to loosen the lug nuts on both rear wheels. Don’t remove them, just break them free.
Using a floor jack, lift the rear of the ATV and securely place jack stands under the frame. Never work under a vehicle supported only by a jack. Wiggle the machine to ensure it’s stable before proceeding.
Remove the rear wheels and set them aside.

Step 2: Disassembly and Removal

Place a drain pan under the differential and remove the drain plug. Let the old, smelly gear oil drain completely.
Disconnect the Driveshaft: Remove the four bolts connecting the rear driveshaft to the differential’s pinion yoke. You may need to use a pry bar to gently separate it. Secure the driveshaft out of the way with a bungee cord.
Remove the Axles: Start by removing the cotter pin from the axle nut and then remove the large axle nut itself. You’ll likely need a big socket and a breaker bar. Then, remove the upper and lower A-arm bolts from the wheel hub (knuckle) to allow you to swing the hub assembly out and pull the axle shaft out of the differential. A gentle tap on the end of the axle with a dead-blow hammer can help.
Unbolt the Differential: The differential is typically held in by several large bolts that go through the frame. Carefully remove these mounting bolts. The differential is heavy, so be prepared to support its weight as you remove the final bolt.
With all bolts removed, carefully wiggle and lower the old differential out of the frame.

Step 3: Installation of the New Differential

Clean Everything: This is one of the most important can am outlander rear differential replacement tips. Clean the mounting points on the frame, the driveshaft yoke, and the splines on your axles. Any dirt or grime can cause improper seating and future problems.
Position the New Unit: Carefully lift the new differential into place. It can be awkward, so a second set of hands is helpful. Loosely thread in all the mounting bolts to hold it in position.
Torque to Spec: Using your torque wrench, tighten the differential mounting bolts to the manufacturer’s specified torque. Check your service manual for the exact values. This is critical for safety and longevity.
Reinstall Axles and Driveshaft: Apply a light coat of anti-seize to the axle splines and carefully slide them back into the new differential until they click into place. Reassemble the hub and A-arms. Reconnect the driveshaft, applying blue threadlocker to the bolts and torquing them to spec.
Torque Axle Nuts: Reinstall the large axle nuts and torque them to the proper specification. This is another critical torque setting. Install brand new cotter pins.

Post-Installation Best Practices: Your Differential Care Guide

You’ve done the hard part! But the job isn’t over yet. Following these post-installation steps is essential for the health and longevity of your new differential. This is your essential can am outlander rear differential replacement care guide.

First, fill the new differential with the correct type and amount of gear oil. Fill it until the fluid is level with the bottom of the fill hole. Reinstall the fill plug securely.

Next, reinstall your wheels and snug up the lug nuts. Lower the ATV off the jack stands and then perform the final torque on the lug nuts in a star pattern.

Finally, perform a gentle break-in procedure. Drive the ATV for 15-20 minutes, avoiding hard acceleration or heavy loads. This allows the new gears to mesh properly. After the first ride, let it cool completely and re-check the gear oil level and check for any leaks. One of the best practices is to change the gear oil after the first 10-20 hours of use to remove any metal shavings from the break-in process.

Choosing Your Replacement: OEM vs. Aftermarket Differentials

When you’re shopping for a new differential, you’ll face a choice: stick with the original factory part (OEM) or upgrade to an aftermarket unit? Both have their merits, and the right choice depends on your riding style and budget.

OEM Differentials

Pros: Guaranteed fit and function. You know it’s exactly what the engineers designed for your machine.
Cons: Can be more expensive and may have the same potential weaknesses as the part that just failed.

Aftermarket Differentials

Pros: Often built stronger with superior materials (like billet aluminum housings or stronger gears). Can be a significant performance upgrade and sometimes more affordable than OEM. Brands like SuperATV or Turner Cycles are popular choices.
Cons: Quality can vary between brands. You need to do your research to ensure you’re buying from a reputable company.

For most trail riders and DIY mechanics, a high-quality aftermarket differential often provides the best balance of performance, durability, and value, delivering significant benefits of can am outlander rear differential replacement beyond just fixing the problem.

Sustainable & Eco-Friendly Differential Replacement Tips

Being an off-roader means respecting the trails and the environment. A sustainable can am outlander rear differential replacement is easier than you think. The most crucial step is proper fluid disposal.

Never, ever dump used gear oil on the ground or down a drain. It is highly toxic. Pour the old oil from your drain pan into a sealed container (like an old milk jug, clearly labeled). Most auto parts stores and local recycling centers will accept used motor oil and gear oil for free. This is the cornerstone of an eco-friendly can am outlander rear differential replacement.

Additionally, thoroughly clean and recycle the old metal differential housing. Most scrap metal yards will gladly take it off your hands.

Frequently Asked Questions About Can Am Outlander Rear Differential Replacement

How long does it take to replace a Can-Am rear differential?

For a first-timer with the right tools, plan for a full afternoon or about 4-6 hours. An experienced mechanic can often do it in 2-3 hours. Don’t rush the process; take your time and do it right.

Can I rebuild my old differential instead of replacing it?

Yes, rebuilding is an option, especially if only the bearings or seals have failed. However, it requires special tools like a press and dial indicators to set the gear backlash and preload correctly. For most DIYers, a complete replacement is a more straightforward and reliable repair.

What is the most common cause of differential failure?

The most common problems leading to failure are water contamination and fluid neglect. Water gets in through bad seals, mixes with the oil, and destroys the bearings and gears. Simply checking and changing your differential fluid regularly is the single best thing you can do to prevent a costly replacement.

Tackling a major repair like a can am outlander rear differential replacement can feel intimidating, but it’s an incredibly rewarding project. You not only save a significant amount of money on labor costs, but you also gain a deeper understanding of your machine. By following this guide, working safely, and double-checking your work, you can get your Outlander back on the dirt where it belongs.

Remember to consult your specific service manual for exact torque specs and fluid capacities. Now, gear up, get in the garage, and get that beast running like new.

Happy wrenching, and stay safe on the trails!

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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.