2002 Grizzly 660 Cracked Rear Differential

Hello everyone,
New member hear and glad to be part of the website. I have been a lurker for awhile and have found a lot of very useful information from the site.

I have an 02′ 660 and had noticed the rear differential clicking when torque is applied. I had tightened up the bolts on several occasions, but it was a short fix. Finally, I decided to rip it apart before there was any significant damage done to the drive train.

Initially, my plan was to have the aluminum sleeved because I figured the holes had been wallowed out, but once I finally got it all pulled out, I found a crack and a piece of the aluminum missing on the nut end of the front mounting bolt.

My question is – can this still be fixed by sleeving the hole? Or do I need to buy a new differential and replace the old? Everything else seems to be in good working order. If it needs to be replaced, any ideas where people are getting theirs? I have no interest in buying a used one and moving all of the gears over. I just don’t have the time for that big of a project.

I tried to post some pictures, but you have to have 10 posts in order to post them. I can forward if someone would like to post them?

Any help or suggestions would be greatly appreciated.

Thank you!

2002 Grizzly 660 Cracked Rear Differential

Hello everyone,
New member hear and glad to be part of the website. I have been a lurker for awhile and have found a lot of very useful information from the site.

I have an 02′ 660 and had noticed the rear differential clicking when torque is applied. I had tightened up the bolts on several occasions, but it was a short fix. Finally, I decided to rip it apart before there was any significant damage done to the drive train.

Initially, my plan was to have the aluminum sleeved because I figured the holes had been wallowed out, but once I finally got it all pulled out, I found a crack and a piece of the aluminum missing on the nut end of the front mounting bolt.

My question is – can this still be fixed by sleeving the hole? Or do I need to buy a new differential and replace the old? Everything else seems to be in good working order. If it needs to be replaced, any ideas where people are getting theirs? I have no interest in buying a used one and moving all of the gears over. I just don’t have the time for that big of a project.

I tried to post some pictures, but you have to have 10 posts in order to post them. I can forward if someone would like to post them?

Any help or suggestions would be greatly appreciated.

Thank you!