Missing bolt on a bracket connecting the rear gear box to the back of the engine.

[Dusted]

Cannot find part number or the bracket in the assembly diagram, neither could the dealer. Its underneath the starter.

 

[Dusted]

Found the part in the Drive train clutch assembly.

 

[Scrappy]

I was changing my oil today and noticed a bolt hanging out of my skid plate. Once I removed the rear plastic skid plate I could see where it came from. It is the same bolt that you had fall out except mine broke off! Either the bolt was defective or Polaris overtightened it. It will be interesting to see if the dealership can get Polaris to pay for it. Anyone know how many bolts are securing the gearbox?

 

[Dusted]

Take a look at Shop Parts by Assembly Diagram under drive train , Main gearcase mounting.

 

[Scrappy]

Just so happens I was looking at that when you posted. I can't seem to find it on the Polaris website. It is labeled W.T 8.8 like yours and is 15mm.

 

[Dusted]

Just so happens I was looking at that when you posted. I can't seem to find it on the Polaris website. It is labeled W.T 8.8 like yours and is 15mm.

I believe the bolt I replace was found on the clutch assembly and the part # 7518531

 

[Scrappy]

Ah, yes, I see it now! You mentioned that in your original posts last year and I thought you meant you somehow physically found it in YOUR clutch assembly. Doh!

Looks like there are only two bolts holding the clutch cover assembly on so I will need to get it replaced. Thanks.

 

[Scrappy]

Ah, yes, I see it now! You mentioned that in your original posts last year and I thought you meant you somehow physically found it in YOUR clutch assembly. Doh!

Looks like there are only two bolts holding the clutch cover assembly on so I will need to get it replaced. Thanks.

Update on this:

Polaris has refused to pay to replace the busted bolt. My dealership agrees that it was clearly overtightened at the factory. This will be the last Polaris product I ever purchase!

To make matters worse the extended warranty that I bought through my dealership is refusing to pay for it as well.

And as I feared, the engine needs to be pulled to access the location of the busted bolt. I am not a happy camper!

 

[Dusted]

Update on this:

Polaris has refused to pay to replace the busted bolt. My dealership agrees that it was clearly overtightened at the factory. This will be the last Polaris product I ever purchase!

To make matters worse the extended warranty that I bought through my dealership is refusing to pay for it as well.

And as I feared, the engine needs to be pulled to access the location of the busted bolt. I am not a happy camper!

That is tough to hear .

Cannot find part number or the bracket in the assembly diagram, neither could the dealer. Its underneath the starter.View attachment 3483View attachment 3483

Update on this:

Polaris has refused to pay to replace the busted bolt. My dealership agrees that it was clearly overtightened at the factory. This will be the last Polaris product I ever purchase!

To make matters worse the extended warranty that I bought through my dealership is refusing to pay for it as well.

And as I feared, the engine needs to be pulled to access the location of the busted bolt. I am not a happy camper!

Read into your extended warranty , that bolt is not a

Take a look at Shop Parts by Assembly Diagram under drive train , Main gearcase mounting.

That is not a wear item ,totally should be covered . The extended warranty is only as good as your dealer.

 

[Scrappy]

Yes, that was my initial response as well. If they don't cover "wear and tear items" nor manufacturing defects then what does it actually cover? I am really struggling with that. My warranty is through Western Services and my dealer never actually shared any paperwork from them. However, I doubt I would have read anything in it that would have given me pause.

At this point I am not pissed at my dealer just yet and they are still trying to resolve this. However, I am disappointed with Polaris and am now very concerned about the quality of their products. This thread outlines one case each of an under-torqued and an over-torqued bolt to the engine block that is not accessible without pulling the engine. I wonder how many other Xpeditions are out there with the same missing bolt that no-one has noticed just yet? It really makes me wonder what tolerances they are applying to the rest of the engine? Yikes!!

 

[cek]

Mine had the same bolt broken off. Found it while replacing the driveshaft. I was able to drill it and remove it myself. It’s a 10x1.5 30mm I believe. I removed the lower bolt to get the size. I pulled the shifter cable bracket and zip tied the hoses to the outside. Was able to drill from under the car while on my lift. I would have taken more pics if I knew it was an issue for others.

 

[Scrappy]

Mine had the same bolt broken off. Found it while replacing the driveshaft. I was able to drill it and remove it myself. It’s a 10x1.5 30mm I believe. I removed the lower bolt to get the size. I pulled the shifter cable bracket and zip tied the hoses to the outside. Was able to drill from under the car while on my lift. I would have taken more pics if I knew it was an issue for others.

Thanks! That is very helpful. I will let the dealership know it is possible without pulling the engine.

 

[Scrappy]

Another update and this one is a shocker:

Yesterday, I sent an email to Polaris expressing my dissatisfaction over this issue. I included a link to this forum for more details about it. They just reached out to me and informed me that they elevated the case and will now cover the repair! They also said they frequently read this forum and really value the information and feedback that it provides.