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New 2012 500 Crew Transfer Case Allen Plug

This is a discussion on New 2012 500 Crew Transfer Case Allen Plug within the Full Size Ranger Discussion forums, part of the Polaris Ranger Forum category; To gain more seating traded my bullet proof Rhino for a new Ranger 500 Crew. Our ranch is 120 miles from town. Out of necessity, ...

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Old 06-03-2012, 10:39 PM   #1
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New 2012 500 Crew Transfer Case Allen Plug

To gain more seating traded my bullet proof Rhino for a new Ranger 500 Crew. Our ranch is 120 miles from town.

Out of necessity, I do my own service work on all our ranch equipment. Went change the Ranger's front transfer case and the inspection bolt was over torqued and the recessed head stripped enough I can't get it out.

Does anyone know if Ranger offers aluminum bolts (socket type head) instead of the hokey recessed allen bolt set up for the drain plug and front rear inspection plugs?

I'm still scratching my head over the front grill where they bolted the bottom of the grill but welded the top? If they had bolted the top too, I could have serviced the transfer case without becoming an acrobat.

Thanks everyone.
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Old 06-04-2012, 06:30 AM   #2
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They are not designed so the owner can service them easily, that would not be good for their dealer network and after sales. Its big in the powersports industry to get the customer back to the dealer for all service, its where they make the most profits.
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Old 06-04-2012, 03:41 PM   #3
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Thanks Z71.

I guess if you live near a city. But for those of us who live and work in the back country having to go to town 120 miles away to simply service an ATV is hard to swallow.

If that's Polaris' policy line , I'll probably head back to Yamaha when they offer a 4 passenger. We use ours in very rough country and can't afford to spend $100 in fuel plus time spent when we need service work. Rhinos are very easy to service.

In the meantime, we'll fabricate our own plugs, cut the grill down and install front grill access bolts to service it.
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Old 06-04-2012, 06:32 PM   #4
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i just serviced my 09 700xp drained and refilled all fluids, i didnt find any particular part of mine too difficult, but thats my machine.. now that ive done it once, i feel good saying i could drain ALL fluids and refill in less than 60 minutes.. i feel your pain, no way id run 120 miles for service.. then again i do my best not to buy anything i cant service myself.
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Old 06-04-2012, 08:16 PM   #5
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Agree.

My neighbor has a new 800xp and his front transfer case is easy to access. But, he complained about the access to the rear case.

On the 500 crew, access to rear case isn't a problem except the recessed bolt.

Otherwise, it's fairly easy to service overall. It just takes one problem like I've got to hold the herd up and cost me money.
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Old 06-07-2012, 12:39 PM   #6
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Remove the plug, and find another one the same thread pattern and diameter that's not recessed. I'm sure the local hardware store should have something like that.
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Old 06-07-2012, 09:17 PM   #7
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They got it out. Was over torqued. I think 12 ft/lbs is where it should have been.

We're contacting a fastner company to get a hex bolt/socket set up with the right length and threaded to the case fill/drain holes.

Re tires. Anyone have a recommendation for 6 ply heavy duty A/T tires to be used in severe off road rocky mountain conditions? Dealer only shows Maxxis A/Ts' for the front and rear in stock size for the 2012 500 crew.

Without power steering, I am reluctant to go larger sizes. It's a beast to turn as it is. Looks like 6 ply choices are slim.
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