There are 4 major reasons that the drive unit fails. 1) the transfer gear is a pressed on gear then welded on causing undue stress risers and weaking of the hard surface of the gear teeth. 2) the 07 reverse shift fork was a welded fabricated fork and again there were too many variables that caused failure because of either twisting of the forks during hard engagement or breakage of the weld. 3) The leakage of fluid due to the bolt distance being too far between the lower right 2 bolts and the case flexing in that area causing the sealant to separate and then lose of fluid and then internal gear failure. 4) Improper engagement of reverse or forward due to electrical current issues ( even with the use of the current control module ) especially when cold conditions exisit. There have been several updates to the 08 gear box, including the gasket to eliminate leakage and a new forged fork.
We have addressed all 4 issues with our Diamond Lite Drive. We use our exclusive 1 piece forged gears ( NO WELDED Gears). A dip stick that you can actually check your fluid level and condition of oil everytime you use your sled without taking a bolt out and wondering what your level is. A new exclusive case that is a direct replacement and no electrical draws. For all 07 and 08 sleds there is a genuine 11 lbs weight loss also. For the 09 sled there is a genuine 4 lbs weight loss besides being much more durable ( especially for the mod motors)
Sorry for the lenghty response but we feel the Arctic Cat rider needs to know the real reasons for the failures and how to correct them. You can call us about any of your concerns.
Thanks, Ray
