FINAL DRIVE

CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

FRONT HUB (2X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

HUB REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
EXPLODED VIEW (2X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

FRONT HUB (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

HUB REMOVAL / INSPECTION / BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . 7.5
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
EXPLODED VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

DRIVE SHAFT / PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

DRIVESHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

FRONT DRIVE SHAFT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

FRONT PROPSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

FRONT GEARCASE CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

AWD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE REASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
BACKLASH PAD (THRUST PAD) ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

REAR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

REAR HUB / BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25

HUB INSPECTION / REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
HUB ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27

REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31

REAR PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32

REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32

REAR GEARCASE (DIFFERENTIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33

GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
OPERATION MODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
DIFFERENTIAL REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
DIFFERENTIAL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41

7.1

FINAL DRIVE
SPECIAL TOOLS
PART NUMBER

TOOL DESCRIPTION

2872608

Roller Pin Removal Tool

8700226

CV Boot Clamp Pliers

2.

Check bearings for side play by grasping the tire / wheel

firmly and checking for movement. Grasp the top and
bottom of the tire. The tire should rotate smoothly without
binding or rough spots.

3.
4.

Remove wheel nuts, washers, and wheel.

Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake line. Use
wire to hang the caliper to prevent possible damage to the
brake line.

5.
6.

Remove hub cap, cotter pin, front spindle nut, and washer.
Remove the spindle from the backside of the strut. Rotate
each bearing by hand and check for smooth rotation.
Visually inspect bearing for moisture, dirt, or corrosion.
Replace bearing if moisture, dirt, corrosion, or roughness
is evident. Inspect the spindle splines for wear.

TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
ITEM

NUT TYPE

Aluminum Wheels
Lug Nut (1)
(Cast)
Steel Wheels
(Black / Camo)

SPECIFICATION
90 ft. lbs. (122 Nm)

Flange Nut (2) 35 ft. lbs. (47 Nm)

Front Spindle Nut

70 ft. lbs. (95 Nm)

Rear & Center

Hub Retaining Nut

110 ft. lbs. (150 Nm)

#2

#1

Aluminum Wheel

Steel Wheel

(LE Models)
90 ft. lbs. (122 Nm)

(Standard Models)
35 ft. lbs. (47 Nm)

FRONT HUB (2X4)

Hub Removal / Inspection
1.

Elevate front end and safely support machine under

footrest / frame area.

CAUTION

Inspect Spindle Shaft

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
Inspect Bearing

7.2

FINAL DRIVE
Hub Installation
1.
2.

7.

Torque the spindle nut to 70 ft. lbs. (95 Nm).

Inspect the hubstrut bearing surface for wear or damage.

Apply grease to spindle.
Grease Spindle

2X4 Spindle Nut Torque:

3.

Install spindle through the backside of the hubstrut. Install

the hub onto the spindle.

70 ft. lbs. (95 Nm)

8.

Rotate wheel and check for smooth operation. There

should not be any binding, rough spots or side play.
9. Install the cotter pin and bend both ends of cotter pin around
end of spindle in different directions.
10. Install hub cap.
11. Install brake caliper using new bolts. Tighten bolts to
specified torque.

Brake Caliper Bolt Torque

18 ft. lbs. (24 Nm)

4.

Apply grease to washer and install with domed side out.

CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.

Out
Cone
Washer
5.
6.

Install spindle nut and hand tighten. Torque the spindle nut
after the wheel is installed.
Install wheel, wheel nuts, washers, and tighten evenly in a
cross pattern and torque to specification.
Refer to Torque Specifications on Page 7.2

7.3

FINAL DRIVE
Exploded View (2X4)
Disc Brake

Stud

Front Hub
Rim
Tire
18 ft. lbs. (24.9 Nm)
Use new bolts with
pre-applied
locking agent.
Wheel Nut
(Spec on page 7.2)

Washer
Spindle Shaft
Dust Cover

Slotted Nut
70 ft. lbs. (95 Nm)

7.4

Cotter Pin

FINAL DRIVE
FRONT HUB (4X4)

5.

Remove hub cap, cotter pin, front spindle nut, and washer.

6.

Rotate each bearing by hand and check for smooth rotation.

Visually inspect bearing for moisture, dirt, or corrosion.
Replace bearing if moisture, dirt, corrosion, or roughness
is evident.

Hub Removal / Inspection

1.

Elevate front end and safely support machine under

footrest / frame area.

CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
2.

Check bearings for side play by grasping the tire / wheel

firmly and checking for movement. Grasp the top and
bottom of the tire. The tire should rotate smoothly without
binding or rough spots.

Rotate Bearing

7
3.
4.

Remove wheel nuts, washers, and wheel.

Remove the two brake caliper attaching bolts. CAUTION:
Do not hang the caliper by the brake line. Use wire to hang
the caliper to prevent possible damage to the brake line.

Hubstrut Bearing Replacement

Bearing Removal
1.

Remove outer snap ring.

2.

From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown in Step 3.

7.5

FINAL DRIVE
3.

Drive bearing out evenly by tapping on outer race only.

Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.

Hub Installation
1.

Inspect the hubstrut bearing surface for wear or damage.

2.

Apply grease to drive axle spindle.

3.

Install spindle through the backside of the hubstrut. Install

the hub onto the spindle.

4.

Apply grease to washer and install with domed side out.

NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
4.

Inspect bearing hubstrut housing for scratches, wear or

damage. Replace hubstrut housing if damaged.

Bearing Installation
5.

6.

Out

Thoroughly clean the hubstrut housing and the outer race

on the new bearing. Be sure that all oil residue has been
removed from each surface.
Apply Loctite RC 680 to the outer circumference of the
new bearing race and carefully install the new bearing into
the strut housing.

Cone
Washer
5.

Install spindle nut and tighten to specification.

4X4 Spindle Nut Torque:

70 ft. lbs. (95 Nm)
6.

Install a new cotter pin. Tighten nut slightly if necessary

to align cotter pin holes.

7.

Rotate wheel and check for smooth operation. Bend both

ends of cotter pin around end of spindle in different
directions.

8.

Install hub cap.

9.

Rotate hub. It should rotate smoothly without binding or

rough spots or side play.

Apply Loctite RC 680

NOTE: Use care to not allow any of the Loctite

compound to get in the bearing.
7.

Wipe the housing clean of any excess compound and install

the retaining ring.

7.6

FINAL DRIVE
10. Install brake caliper using new bolts. Tighten bolts to
specified torque.

CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.

18 ft. lbs.
(24 Nm)

11. Install wheel, washers, wheel nuts, and tighten evenly in a

cross pattern to specified torque.
Refer to Torque Specifications on Page 7.2
Flange Nuts:
Flat side against wheel

Brake Caliper Bolt Torque

18 ft. lbs. (24 Nm)

Exploded View (4X4)

Disc Brake

Stud

Front Hub

Rim

Tire

18 ft. lbs. (24 Nm)

Use new bolts with
pre-applied
locking agent.

Wheel Nut
(Spec on page 7.2)

Dust Cover

Washer
Slotted Nut
70 ft. lbs. (95 Nm)

Cotter Pin

7.7

FINAL DRIVE
DRIVE SHAFT / PROPSHAFT
Exploded View
RANGER 4X4 Front Driveshaft
30g Grease Packet
CV Joint

30g Grease Packet

Plunging Joint

Inner Clamps

Circlip
Boots

Clamp

Clamp

Joint Kit

RANGER 4X4 Front Propshaft

Grease Zerk O-ring

Shaft
Yoke

Front Yoke

RANGER 2X4 & 4X4 Rear Propshaft

Cross & Bearing Kit

O-ring
Spring Pin

7.8

FINAL DRIVE
DRIVESHAFT / CV JOINT
HANDLING TIPS

2.

Check bearings for side play by grasping tire / wheel firmly

and checking for movement. It should rotate smoothly
without binding or rough spots.

3.

Remove wheel nuts, washers, and wheel.

4.

Remove the two brake caliper attaching bolts.

CAUTION: Do not hang the caliper by the brake line. Use
wire to hang the caliper to prevent possible damage to the
brake line.

Care should be exercised during driveshaft removal or when

servicing CV joints. Driveshaft components are precision parts.
Cleanliness and following these instructions is very important to
ensure proper shaft function and a normal service life.
The complete driveshaft and joint should be handled by
getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the driveshaft
joints.
Over-angling of joints beyond their capacity could
result in boot or joint damage.
Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
The driveshaft is not to be used as a lever arm to
position other suspension components.
Never use a hammer or sharp tools to remove or to
install boot clamps.
Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer
to text for grease capacity of CV joints and CV joint

boots.

FRONT DRIVE SHAFT (4X4)

Removal

5.

Remove the hub spindle nut.

1.

6.

Remove hub.

Elevate front end and safely support machine under

footrest / frame area.

CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.

7.9

FINAL DRIVE
7.

8.

9.

Remove cotter pin and nut from lower A-arm ball joint.
Remove lower A-arm from ball joint.

CV Joint / Boot Replacement

1.

Remove wheel, brake caliper and wheel hub. Refer to

Front Hub Removal for procedure.

2.

Remove cotter pin and castle nut from A-arm ball joint.

3.

Disconnect A-arm from ball joint using a tie rod fork.

4.

Slide strut off end of drive shaft and tie it up out of the way
of the shaft.

5.

Remove clamps from rubber boot using the proper boot

clamp pliers.

Pull strut assembly out while pivoting front drive shaft

downward until it clears strut assembly.

With short sharp jerks, remove drive shaft from front

gearcase.

CV Boot Clamp Pliers:

Earless Type - 8700226

7.10

FINAL DRIVE
6.

Remove the large end of the boot from the CV joint, slide
the boot back and separate the wheel spindle and CV joint
assembly from the axle shaft by pulling the shaft sharply
outward, away from the CV joint. It may be necessary to
tap the CV joint assembly outward with a soft faced
hammer.

FRONT SHAFT (4X4)

Boot Capacity
30 Grams

Retaining Ring

Joint Capacity*
30 Grams

Pull shaft to remove

from CV joint
7.

Remove small clamp and boot from driveshaft.

If the unit has been operated with a damaged boot, the CV
joint grease may be contaminated. Inspect the grease
carefully for contamination, and clean the joint thoroughly
if necessary. Front drive axle outer boot replacement
requires 30g of grease. Inner boot replacement requires 20g
of grease. If either of the joints are cleaned, double the
amount of grease is required. Refer to information below
and illustration to the right.

Boot Replacement Grease Requirement:

Outer
CV Joint Grease - 30g PN 1350046
Inner
Plunging Joint Grease - 20g PN 1350059
8.

Joint Capacity**
20 Grams
Boot Capacity
20 Grams

7
*CV joint capacity: 30g if boot is replaced only.
Another 30g (60g total) if joint is cleaned.
**Plunging joint capacity: 20g if boot is replaced
only. Another 20g (40g total) if joint is cleaned.

Before installing the new boot, remove all grease from the
boot area and shaft.

NOTE: It is very important to use the correct type

and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint.
9.

Slide the new clamp and boot (small end first) over the
splined shaft, then slide (tap) the CV joint into the splines
of the axle. Install small boot clamp.

10. Add grease through large end of boot.

11. Position large end of boot on CV joint, purge excess air by
partially compressing axle into CV bell, lift one edge of
boot to let out excess air Secure the CV boot with clamp.

7.11

FINAL DRIVE
FRONT PROPSHAFT REMOVAL

Installation
1.

Install new spring ring on drive shaft. Apply an anti-seize

compound to splines. Align splines of drive shaft with
front gearcase and install by lightly tapping on drive shaft
with rubber faced hammer.

1.

Elevate front end and safely support machine under

footrest / frame area.

CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.

2.

Install drive shaft in strut.

3.

Install the lower A-arm onto the lower ball joint, torque nut
to 25 ft. lbs. (35 Nm) and install new cotter pin.

Cotter Pin

4.

25 ft. lbs.
(35 Nm)

2.

Remove wheel nuts and wheel.

3.

Remove cotter pin and nut from lower A-arm ball joint.
Remove lower A-arm from ball joint. (See below)

4.

Use the Roll Pin Removal Tool (PN 2872608), to remove

the roll pin from prop shaft at the front housing. Slide prop
shaft back and away from front housing. Pull sharply
forward to remove from transmission shaft.

NOTE: The roll pin can also be accessed through

the hole in the skid plate shown in the photo below.

Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).

Front Spindle Nut Torque

70 ft. lbs. (95 Nm)

Roll Pin Removal Tool (PN 2872608)

7.12

FINAL DRIVE
NOTE: Remove the drive shaft floor cover to help
align the roll pin removal tool to the roll pin for
removal. The drive shaft can be removed through
the floor covering.

2.

Support inner yoke as shown and drive outer yoke down

(bearing cap out) with a soft face hammer.

3.

Support U-joint in vise as shown and drive inner yoke down

to remove remaining bearing caps.

PROPSHAFT U-JOINT SERVICE

Disassembly
1.

Remove internal or external snap ring from all bearing

caps.

CAUTION

Always wear eye protection.

4.

Force U-joint cross to one side and lift out of inner yoke.

NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct repositioning during installation.

7.13

FINAL DRIVE
Assembly
1.

2.

3.

4.

Install outer
disassembly.

yoke,

aligning

marks

made

before

5.

Repeat Steps 1-3 to install bearing caps on outer yoke.

6.

Seat all bearing caps against snap rings by supporting cross

shaft and tapping on each corner as shown.

7.

When installation is complete, yokes must pivot freely in

all directions without binding. If the joint is stiff or binding,
tap the yoke lightly to center the joint until it pivots freely
in all directions.

Install new bearing caps in yoke by hand. Carefully install

U-joint cross with grease fitting properly positioned
inward toward center of shaft. Take care not to dislodge
needle bearings upon installation of cross joint. Tighten
vise to force bearing caps in.

Using a suitable arbor, fully seat bearing cap in one side.

Continually check for free movement of bearing cross as
bearing caps are assembled.

Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.

7.14

FINAL DRIVE
FRONT GEARCASE
CENTRALIZED HILLIARD

CAUTION

AWD Operation
Engaging Front Gearcase: The AWD switch may be turned on
or off while the vehicle is moving. Initially, the vehicles
electronic system will not enable the AWD until the engine RPM
is below 3100. Once enabled, the AWD remains while the front
gearcase is moving, it will not disengage until the rear wheels
regain traction.
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are
spinning , release the throttle before switching to AWD.

If the rear wheels are spinning, release the

throttle before turning the AWD switch on.
If AWD is engaged while the wheels are
spinning, severe drive shaft and clutch
damage could result.
Roller Cage and Rollers Rotate Inward and Grip the Output hub
for AWD Engagement
Output Hub

Rollers

CAUTION
Switching to AWD while the rear wheels are
spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.
Normal Operation: With the AWD switch off the vehicle
drives only the rear wheels (2 wheel drive). When the AWD
switch is activated it engages the Hilliard, locking both front
axles into All Wheel Drive.
Roller Cage

Roller Cage
& Bearings
Disengagement: As the front and rear wheels gain traction,
rotating very close to the same speed, the front wheels
overdrive the output hubs and the rollers are forced outward,
disengaging the AWD. The vehicle is now back to rear wheel
drive until the next loss of traction.

Armature plate design may

differ from what is shown

Output Hub

Armature
Plate

Coil

Cover

4X4 Engagement: When the AWD switch is activated, a 12

VDC current charges the central coil which creates a magnetic
field. This magnetic field attracts an armature plate keyed to a
roller cage that contains 14 rollers and roller cam. The difference
in rpm by input shaft and front axles the forces the rollers up the
external cam. The rollers engage themselves to the output hubs
that link both front axles, resulting in True All Wheel Drive.

7.15

FINAL DRIVE
Centralized Hilliard Exploded View

3
17 ft. lbs.
(23 Nm)

15

5
6

14

11

10
6

15
17 ft. lbs.
(23 Nm)

20

12
13

14
24

26

16

25
18
23

17

19
22
14

10 ft. lbs.
(14 Nm)

21
8-30 ft. lbs.
(11-41 Nm)

REF#

DESCRIPTION

QTY

REF#

DESCRIPTION

QTY

Set Screw

14

Seal Kit (Includes O-Rings and Seals)

Cover Plate Asm.

15

Screw

11

Thrust Button

16

Input Cover

Thrust Plate

17

Roller Ball Bearing

Armature Plate Shim

18

Pinion Shaft, 11T

Roller Ball Bearing

19

Bushing

Race / Output Hub Asm.

20

Gearcase LH

Dowel Pin

21

Oil Fill Plug

Clutch Housing / Ring Gear

22

Drain Plug Asm. (Includes Plug and Washer) 1

10

Roll Cage Asm (Includes H-Springs)

23

Roller Thrust Needle Bearing

11

Rollers

14

24

Clutch Asm.

12

Bushing

25

Internal Retaining Ring

13

Vent Fitting

26

Armature Plate

7.16

FINAL DRIVE
AWD Diagnosis
Possible
Wear Ring on
Armature Plate

Symptom: AWD Will Not Engage.

1.

Check the gearcase coil resistance. To test the gearcase

coil resistance. Test between the Grey & Brown / White
wires. The gearcase coils should measure between 22.8
ohms and 25.2 ohms.

OK Condition

Front Gearcase Coil Resistance:

22.8--25.2 Ohms
2.

Check the minimum battery voltage at the Gray & Brown

/ White wires that feed the hub coil voltage. There should
be a minimum of 11.0-12.0 Volts present for proper
operation.
Bad Condition
(Wear from coil
on armature plate)
4.

Check to make sure the coil is seated in the U-shaped insert

that is pressed into the gearcase cover. The top of the coil
should be seated below the U-shaped insert. The U-shaped
insert controls the pole gap. If the top of the coil is above
the surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system. If this is the cause order a new Plate Cover
Assembly.
Gearcase Cover

3.

Inspect the armature plate for a consistent wear pattern.

There should one or two distinct wear bands (one band
inside the other). If only one band of wear is present (or if
there is wear between the two bands, inspect the coil area
as indicated in Step 4. A band with an interrupted wear mark
may indicate a warped plate, which may cause intermittent
operation. See the following illustrations.

Coil

U-shaped insert
Armature Plate

Side cutaway view of

Centralized Hilliard cover

Armature plate design may

differ from what is shown

Check for wear bands

7.17

FINAL DRIVE
5.

Inspect the rollers for nics and scratches. The rollers must
slide up and down and in and out freely within the roll cage
sliding surfaces.

8.

The front gearcase and drive shafts can be accessed from

both sides of the vehicle and limited access from the top.

Rollers

Top View - From under hood

9.

Remove the access panel on the side of the vehicle. T-25

screws secure the panel to the frame.

Gearcase Removal
1.
2.
3.

Stop engine, place machine in gear and set parking brake.

Loosen right front wheel nuts slightly.
Elevate and support machine under footrest/frame area.

CAUTION

Left
Side Panel

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing and installing bearings and seals.
4.
5.

Remove right wheel nuts and wheel.

Remove cotter pin, lower ball joint nut, and A-arm from
ball joint.

6.
7.

Repeat Step 1 through Step 5 on the opposite side.

Pull each axle out from the front gearcase, refer to the
"FRONT DRIVE SHAFT REMOVAL" procedure earlier
in this chapter.

7.18

10. Remove the roll pin from the front drive shaft.Remove the
front drive shaft from the front gearcase splines.
11. Remove bolts securing bottom of gearcase to frame.
Remove vent line. Remove gearcase from right side of
frame.

Remove 4 Bolts

FINAL DRIVE
Gearcase Disassembly / Inspection
1.
2.

Remove the roll cage assembly, rollers, and H-springs.

7.

Thoroughly clean all parts. Inspect the rollers (A) for nicks
and scratches. The rollers must slide up and down freely
within the roller cage surfaces (B).
Inspect the ring gear (C) for consistent wear patterns. The
surfaces should be free of nicks and scratches.

Drain and properly dispose of used oil. Remove any metal

particles from the drain plug magnet.
Remove bolts and output shaft cover.

3.

Check the gearcase coil resistance. The resistance value

should meet the specifications listed below.
NOTE: To test the gearcase coils resistance, use the
coil harness. The gearcase coils should measure
between 22.8 ohms and 25.2 ohms.
4.

6.

8.

Remove output shaft assembly

C
A
9.

NOTE: Be careful not to misplace the thrust bearing

located between the two output shafts.
5.

Inspect roll cage (B) sliding surface. This surface must be

clean and free of nicks, burrs or scratches. Remove and
inspect the H-springs.
H-Spring
B

Clean all parts and inspect spacers for wear. Inspect ring
gear for chipped, broken, or missing teeth.

7.19

FINAL DRIVE
10. Use a flat head screwdriver to remove the retaining ring
from the output cover.

13. Remove the output hub (G) from the cover. remove the
thrust bearing (F) from the output hub (G). Inspect the
thrust bearing (F) and the dowel (H).

Retaining Ring
G

F
11. Remove the spacer washer (D), armature plate (E), and
rubber O-ring from the output cover.
D

O-Ring

14. Inspect the magnetic coil (I) in the output housing.

NOTE: See "FRONT GEARCASE DIAGNOSIS"
earlier in this chapter for more details on the coil.
15. Inspect the back lash pad (J) for excessive wear.
NOTE: The backlash for the centralized hilliard is set
at the factory. No adjustment is required, unless the
front cover needs to be replaced, or the back lash
pad screw is removed. See the "Backlash Pad
Adjustment procedure later in this chapter for
details on backlash setting.
J

12. Inspect the armature plate (E) for a consistent wear pattern.
Uneven wear of the armature plate (E) indicates a warped
plate, which may cause intermittent operation.
NOTE: See "FRONT GEARCASE DIAGNOSIS"
earlier in this chapter for more details.
E
I

Armature plate design may

differ from what is shown

7.20

FINAL DRIVE
16. Remove the other output hub (K) from the main gearcase.
Inspect the inner bearing (L) for wear. If there is excessive
wear, replace bearing as needed.

19. Install new seals into the gearcase housing and use new Orings for the gearcase input and output covers.

17. Remove the input cover (M), bearing (N), and the pinion
gear (O). Inspect the pinion gear (O) for chipped, broken,
or missing teeth. Replace the input cover O-ring.

Gearcase Reassembly / Inspection

1.

As mentioned in the disassembly section, replace all Orings, seals, and worn components.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To replace,
press new bearing on to shaft.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement side to side.
4.

Install pinion shaft, bearing, and input cover with new oring and torque bolts to 17 ft. lbs. (23 Nm).

18. Inspect the output shaft bushing. Replace as needed. Clean

the inside surfaces of both gearcase halves.

Input Cover Bolts Torque:

17 ft. lbs. (23 Nm)

7.21

FINAL DRIVE
5.

Install the output hub (A) into the gearcase housing. The
output hub should spin freely.

8.

Install the retaining ring (F) into the output cover. Be sure
the retaining ring is properly seated into the cover.

A
F

6.

Install the other output hub (B) and thrust bearing (C) into
the output cover. Apply a small amount of grease onto the
thrust bearing.

9.

Install the ring gear (G) onto the output hub on the output
cover.
G

7.

Install the armature plate (D) and spacer washer (E) into the
output cover.

Backlash Plate
NOTE: Be sure backlash plate is in place.

7.22

10. Install the rollers and roll cage into the ring gear. Insert the
rollers as the roll cage is installed.

FINAL DRIVE
11. Install the output cover assembly onto the main gearcase.

Backlash Pad (Thrust Pad) Adjustment

1.
2.

Lay the gearcase on the side with the output cover facing
up.
The backlash screw is loctited into place. Use a heat gun to
lightly heat up the loctite on the screw (A).

NOTE: Be sure armature plate tabs are placed into

the slots on roll cage. (See Reference Photo)
Photo for reference only

3.
Armature plate tabs
fit into roll cage slots

Using a hex wrench, turn the back-lash screw out 3-4 turns.
Re-apply red loctite onto the bottom screw threads.

Armature plate design may

differ from what is shown

NOTE: This photo is for reference only, the armature

plate is actually installed in the output cover.
12. Install output cover with new O-ring and torque bolts to 17
ft. lbs. (23 Nm).
NOTE: Be sure the square O-ring is placed flat on
the cover surface. If the O-ring is twisted fluid
leakage may occur.

4.
5.

Turn the screw in until it is lightly seated, then turn the

screw out 1/4 turn.
Set the gearcase upright. Rotate the pinion shaft at least 4
times. This ensures the ring gear completes one full
rotation.

Cover Bolts Torque:

17 ft. lbs. (23 Nm)

7.23

FINAL DRIVE
6.

If a tight spot is felt during rotation, loosen the backlash

screw another 1/8 turn. Perform the previous step again.
Repeat this procedure until the pinion shaft rotates
smoothly 4 times (1 revolution of ring gear).

Gearcase Installation
1.

To install gearcase, reverse removal procedure.Use new

spring pin in front prop shaft.

2.

Torque mounting bolts to 30 ft.lbs. (41 Nm).

4 Bolts
30 ft. lbs. (41 Nm)

Front Housing Mount Bolt Toque:

30 ft. lbs. (41 Nm)
3.

Add the proper lubricant to the front gearcase. Check drain

plug for proper torque. Refer to Chapter 2 for fluid fill and
change information.

Premium Front Drive Hub Fluid

(PN 2871654)
Front Housing Capacity
5 fl. oz. (148 ml)

7.24

FINAL DRIVE
REAR DRIVE
Exploded View
30 ft. lbs.
(41 Nm)

Rear Gearcase

Coil

A-arm bolts
Shaft
Bushings

Shock
Upper A-arm
Bushings

Rear Drive Axle

30 ft. lbs.
(41 Nm)
Caliper
18 ft. lbs.
(24 Nm)

A-arm bolts
Nuts
Bearing
Bushings

Lower A-arm
Carrier Bolt
Shaft

30 ft. lbs.
(41 Nm)
Shaft

Snap Ring

Bushings

REAR HUB / BEARING CARRIER

Hub Inspection

Hub Removal

1.

Support machine securely with rear wheels elevated.

1.

2.

Grasp wheel / hub and check for movement.

Elevate rear end and safely support machine under main

frame area.

3.

If movement is detected, inspect hub, hub nut torque and

bearing condition and correct as necessary.

2.

Check bearings for side play by grasping the tire / wheel

firmly and checking for movement. Grasp the top and
bottom of the tire. The tire should rotate smoothly without
binding or rough spots.

3.

Remove wheel nuts and wheel.

CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.

7.25

FINAL DRIVE
4.

5.

Remove the two brake caliper attaching bolts.

CAUTION: Do not hang the caliper by the brake line. Use
wire to hang the caliper to prevent possible damage to the
brake line.

7.

Remove the upper and lower control arm bolts from the rear
hub / bearing carrier.

8.

Remove the bearing carrier. Inspect the bearing again for

smoothness and side to side movement, replace as needed.

Remove hub cap, cotter pin, front spindle nut, and washer.

Hub Disassembly
1.

Remove outer snap ring (A).

A

6.

Slide the rear hub from the rear drive axle.

2.

From the back side, tap on the outer bearing race with a drift
punch in the reliefs as shown.
NOTE: Drive bearing out evenly by tapping on outer
race only. Once bearing is at bottom of casting,
support casting on outer edges so bearing can be
removed.

7.26

FINAL DRIVE
3.

Inspect the bearing.

NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
4.

Inspect bearing housing for scratches, wear or damage.

Replace housing if damaged.
4.

Hub Assembly
1.

Support bottom of bearing carrier housing. (A) Bearing

Carrier Housing; (B) Bearing; (C) Snap Ring

Hub Installation
1.

Start the wheel bearing carrier onto the drive shaft.

2.

Align the bottom of carrier housing and lower control arm.

Slide the lower control arm bushings into place. Secure
with the lower control arm bolt.

3.

With the driveshaft placed in the wheel bearing carrier,

align the carrier with the top control arm. Secure with the
upper control arm bolt.

2.

Install snap ring into groove.

NOTE: The lower shock bolt may need to be

removed to allow the upper A-arm to move more
freely.

Start bearing (B) in housing (A).

B
A

3.

Press bearing into place until outer race bottoms on

housing.

CAUTION
Use an arbor and press only on the outer race,
as bearing damage may occur.

7.27

FINAL DRIVE
4.

Torque the top and bottom A-arm bolts as shown in the

photo.

REAR DRIVE SHAFT

Removal
1.

Repeat all of the steps in the Rear Hub / Bearing Carrier,

Hub Removal section.

2.

Remove upper carrier bolt. Slide the rear drive shaft out of
the bearing carrier by pulling the bearing carrier assembly
outward and tipping it down to remove the shaft.

3.

Pull the rear drive shaft straight out of the frame. Use short
sharp jerks to free the circlip from the gearcase. The circlip
holds the drive shaft in the gearcase.

4.

Inspect the axle splines and CV boots for any damage.

30 ft. lbs.
(41 Nm)

5.

Install the hub assembly onto the rear drive axle.

6.

Install the washer with domed side out. Install the spindle
retainer nut.

7.

Install the wheel, washers, and wheel nuts. Torque wheel

nuts to specification. See Torque Specifications table on
page 7.2

8.

Lower the vehicle. Torque the spindle retaining nut to 110

ft.lbs. (149 Nm). Install a new cotter key and the hub cap.

110 ft. lbs

(149 Nm)

7.28

FINAL DRIVE
CV Joint / Boot Replacement
1.

Remove clamps from rubber boot(s) using the CV Boot

Clamp Pliers (PN 8700226) (A).
A

NOTE: When replacing a damaged boot, check the

grease for contamination by rubbing it between two
fingers. A gritty feeling indicates contamination. If
the grease is not contaminated, the boot can be
replaced without cleaning the CV joint. Use the
recommended amount of grease for boot
replacement only.
4.
5.

Remove boot from the shaft.

Thoroughly clean and dry the CV joint and inspect ball
tracks and cages for wear, cracks or other damage.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
joint only if components are cracked, broken, worn
or otherwise unserviceable.

CV Boot Clamp Pliers:

Earless Type - 8700226
2.

6.

Remove the large end of the boot from the CV joint and
slide the boot back.

Place a new snap ring in the groove of the CV joint inner

hub, with tabs facing the shaft as shown.

Tabs face the shaft

Snap ring located in recessed area

Snap ring

7
NOTE: Photo above is shown without shaft for
clarity. Wipe grease away from recess in CV joint
inner hub to locate snap ring
3.

Open the snap ring using a snap ring pliers or small needle
nose pliers. Tap CV housing off shaft with a soft faced
hammer while holding snap ring open.
Spread ends of snap ring
to remove joint from shaft

7.

Before you assemble the CV joint, slide the new boot (small
end first) and clamp over the splined shaft.

7.29

FINAL DRIVE
8.

Refit CV joint on the shaft by tapping with a plastic hammer

on the joint housing. Take care not to damage threads on
the outboard CV joint. The joint is fully assembled when
the snap ring is located in the groove on the shaft.
Tap joint onto shaft

NOTE: It is very important to use the correct type

and quantity of grease by using the grease
contained in the boot kit. DO NOT use a substitute
grease and DO NOT overfill or underfill the CV joint.
9.

Fill the CV joint and/or boot with the recommended type

and amount of grease. Rear drive shaft inner or outer boot
replacement requires 50g of grease if the CV joints were not
disassembled.
NOTE: If the joints were disassembled and cleaned,
refer to the call-out below or Figure 7-31 for the
correct amount of grease required.

11. While pulling out on the CV shaft, fully extend the CV joint
and slide a straight O-ring pick or a small slotted screw
driver between the small end of the boot and the shaft. This
will allow the air pressure to equalize in the CV boot in the
position that the joint will spend most of its life. Before you
remove your instrument, be sure the small end of the boot
is in its correct location on the axle.

12. Install the small clamp on the boot.

REAR SHAFT
CV Joint
Joint Capacity*
25 Grams
Retaining
Ring
Large Clamp

Boot Replacement Grease Requirement:

Inner Plunging Joint Grease - PN 1350047
Only boot replacement - 50g
Boot replacement w/joint cleaning - 100g
Outer CV Joint Grease - PN 1350047
Only boot replacement - 50g
Boot replacement w/joint cleaning - 75g

Grease
PN 1350047
Boot Capacity
50 Grams

Boot

Small Clamp
Boot Capacity
50 Grams

Boot
Grease
PN 1350047

10. Remove excess grease from the CV joint's external surfaces

and position the boot over the housing, making sure the
boot is seated in the groove. Position clamp over the large
boot end and make sure clamp tabs are located in slots.
NOTE: Before tightening boot clamp on inboard
joint, make sure any air pressure which may have
built up in joint boot has been released. The air
should be released after the plunging joint has been
centered properly. Tighten boot clamp using boot
clamp pliers.

Large Clamp
Retaining
Ring

Joint Capacity*
50 Grams

Plunging Joint
Spring Ring

Figure 7-31

7.30

FINAL DRIVE
Installation
1.

4.

Lift bearing carrier into place and install the bolt into the
upper control arm. Torque bolt to 30 ft. lbs. (41 Nm).

Slide the rear drive axle into the bearing carrier hub.

30 ft. lbs.
(41 Nm)

2.

Install a new circlip onto the rear drive shaft. Apply AntiSeize Compound onto the rear driveshaft splines (both
ends).

5.

Install hub, domed washer (domed side out) and nut.

Torque rear spindle nut to 110 ft. lbs. (149 Nm). Install new
cotter pin and hub cap.

Apply Anti-Seize

New Circlip

3.

Rear Hub Nut Torque:

Reinstall the rear driveshaft into the rear gearcase. Be sure

the circlip is securely fit into the rear gearcase. Use a rubber
mallet to tap on the outboard end of the driveshaft if
necessary.

110 ft. lbs. (149 Nm)

6.

Install rear wheel and torque washers and wheel nuts to

specification. See Torque Specifications on page 7.2.
110 ft. lbs.
(149 Nm)

Flat washer

Wheel Nut (4)

Out
Cone
Washer

Cone
washer
dome to
outside

7.31

FINAL DRIVE
REAR PROPSHAFT

4.

Slide the propshaft off the transmission shaft and rear

gearcase input shaft. Orientate the shaft so that its parallel
with the frame supports as shown below.

5.

Remove the shaft by placing the brake disc over the top of
the rear frame support and under the front frame support.

Removal
1.

Remove the pin clips from upper and lower cargo box
shock pins and remove shock. Carefully allow cargo box
to rest in the dump position as you remove the propshaft.

Rear Frame
Support

WARNING
Support the cargo box while the shock is removed
to prevent injury or damage.
2.

Front Frame
Support

Use the Roll Pin Removal Tool (PN 2872608), to remove

the roll pin from prop shaft at rear of transmission.

Installation

3.

1.

When installing the propshaft, ensure that the shaft is

touching the rear frame support and reinstall the shaft the
same way it was removed with the brake disc over the top
of the rear frame support and under the front frame
support.

2.

Slide the shaft onto the rear gearcase input shaft and then
slide it onto the transmission shaft.
Install a new roll pin into the propshaft
Install the parking brake caliper and torque mounting bolts
to 18 ft. lbs. (24 Nm).
Install cargo box shock, mounting pins and pin clips.

Remove the two bolts that secure the rear parking brake
caliper. Suspend the brake caliper assembly from the frame
with a piece of wire. (Refer to Chapter 9 for more
information on the rear parking brake)

3.
4.
5.

7.32

FINAL DRIVE
REAR GEARCASE (DIFFERENTIAL)
General Operation
The RANGER rear gearcase has three traction operational
modes: AWD, Differential Lock, and Differential Unlock.
Locking the rear differential is beneficial in low traction and
rough terrain conditions. Unlocking the rear differential makes
maneuvering easier and minimizes damage to turf and sensitive
terrains.

When the clutch gear is unlocked the rear axle becomes a

differential. When its locked it becomes a solid rear axle
increasing traction. (See images below)
Clutch Gear

Shift Yoke

AWD
Shift yoke slides clutch gear to
lock and unlock the rear differential
Differential - Locked
Clutch Gear
Differential - Unlocked

When the Unlocked option is chosen on the selector, the rear

differential becomes unlocked for tighter turns. An electrical
solenoid mounted on the rear axle housing actuates the shift
yoke and slides the clutch gear to lock and unlock the rear axle
housing.
When switch position is set
to Unlock, the solenoid is
powered and the
plunger extends
to disengage the
clutch gear and
unlock the
axle housing.

Locked Mode
Clutch Gear

IRS Axle

Locked
Locked

Unlocked Mode
IRS Axle

Clutch Gear
Unlocked

7.33

FINAL DRIVE
Operation Modes

Differential Unlocked

Differential Locked

Both rear wheels rotate at same speed.

Rear wheels can rotate at different

speeds. (Allow for sharper turning)

AWD Mode

Rear Wheels rotate as same speed.

Front Wheels rotate as same speed when AWD activated.

7.34

FINAL DRIVE
Differential Removal

Differential Disassembly

1.

IMPORTANT: The pinion gear assembly is NOT

intended to be disassembled from the case, as it
requires special OEM tooling in order to properly
reassemble. If there is any damage to the pinion gear,
bearings or case, the assembly must be replaced.
Pinion and ring gear shimming information is NOT
provided due to OEM manufacturing requirements.

2.
3.

Follow Rear Drive Shaft Removal procedure to remove

the drive axles from each side of the rear differential.
Disconnect the differential solenoid 2 wire harness.
Remove the four bolts that secure the rear differential
brackets to the frame.

1.
2.

Drain and properly dispose of used gearcase fluid.

If necessary, remove the rear differential mount brackets
from the rear differential.

3.

Remove the bolts that secure the carrier cover (A) bolts to
the carrier housing (B).

Remove 2 bolts from each side

4.

Carefully pull the rear differential case assembly from the

frame. Let the rear propshaft slide off of the rear
differential.

Remove Cover Bolts

7.35

FINAL DRIVE
4.

Remove the differential assembly (C) from the housing.

Inspect the bevel gear teeth for chipped, worn, or broken
teeth.

6.

Remove the differential lock solenoid (F) from the carrier

housing by turning the solenoid counterclockwise.
F

7.

5.

Remove the bearings from each side of the carrier assembly

(C). Inspect the bearings (D) for smoothness and wear. Be
sure to keep the shims (E) together for reassembly.

Inspect the tip of the solenoid (F) for wear. If the tip of the
solenoid is flat the solenoid may need to be replaced.

D
8.

Remove the clutch gear (G) from the carrier cover (B) and
shift yoke (H).

J
K
D

7.36

FINAL DRIVE
9.

Inspect the shift yoke (H), shift lever (J), and shift lever
return spring (K).

12. Thread the bolt into the shift yoke pivot shaft (L).

H
13. Carefully pull the shift yoke pivot shaft (L) out of the carrier
cover.
10. Remove the set screw.
L

11. Remove the shift yoke pivot shaft (L) Use a 1/4 in.- 20
coarse thread bolt approximately 3 in. long to thread into
the pivot shaft.

14. Remove the shift lever (M) and springs (N) from the shift
yoke (H). Inspect the components for wear and replace as
needed.

7.37

FINAL DRIVE
15. Remove the pinion shaft seal (P) using a seal puller.

2.

Install the original shims (A) onto the differential assembly

(B) on both sides. Install the bearings (C), replace with new
bearings if needed.
B

C
A

16. SPECIAL NOTE: The Pinion assembly is NOT intended

to be disassembled, as it requires special OEM tooling in
order to properly assemble the pinion assembly. If there is
any damage to the pinion gear, bearings or case, the
assembly must be replaced.

3.

Install the differential assembly into the carrier housing.

4.

Install the spring lever and shift yoke into the carrier cover,
if previously removed.

Differential Assembly
1.

Replace all O-rings, seals, and worn components. Replace

the O-ring and oil seal on the carrier housing.
NOTE: Grease all seals and O-rings with Polaris All
Season Grease (PN 2871322) upon assembly.

7.38

FINAL DRIVE
5.

Assemble the shift yoke (D), shift lever (G), spring lever
(F), and return spring (E).

8.

Install the new lightly greased O-ring (K) onto the carrier
cover.

H
Carrier Cover

F
E

D
K

6.

Use the bolt that was used to remove the shift yoke pivot
shaft (H) to reinsert the shaft into the carrier cover. Place
the shift yoke assembly into the carrier cover and secure
with the shift yoke pivot shaft (H).
Install Shift Yoke Assembly

9.

Install the carrier cover bolts. Tighten and torque the bolts
in a criss cross pattern to 25-35 ft.lbs. (34-48 Nm).
25-35 ft. lbs.
(34-48 Nm)

7
7.

Install the differential lock solenoid into the carrier cover.

Torque solenoid to 30-40 ft. lbs. (41-54 Nm).

10. Install the rear differential mount brackets from the rear
differential onto the rear differential. Torque the bracket to
differential bolts to 26-33 ft.lbs. (35-45 Nm)

30-40 ft. lbs.

(41-54 Nm)
26-33 ft. lbs. (35-45 Nm)
Bracket to Differential

7.39

FINAL DRIVE
Differential Installation
1.

Place the differential assembly into the frame. Torque the

bracket to frame bolts to 38-42 ft.lbs. (35-45 Nm).

Bracket to Frame
38-42 ft. lbs. (35-45 Nm)

2.

Slide the rear propshaft onto the rear differential input shaft.

3.

Reverse the removal procedure for the rest of the

installation.

4.

Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear

carrier. Refer to maintenance information in Chapter 2 for
more details. Torque drain plug to 30-45 in.lbs. (3-5 Nm).
Torque fill plug to 40 ft.lbs. (54 Nm).

Fill Plug
40 ft. lbs.
(54 Nm)

Drain Plug
30-45 in. lbs.
(3-5 Nm)

Rear Gearcase capacity:

18 fl. oz. (532 ml)
or
0.75 (1.9 cm) below bottom of fill plug
hole threads - See Chapter 2

7.40

FINAL DRIVE
Differential Exploded View
8

30-45 in. lbs.

(3-5 Nm)

10

ft. lbs.
11 40
(54 Nm)

20
5

4
3
1

12
6

13

12

19

14

17

38

21

18

15 16

37

25-35 ft. lbs.

(34-48 Nm)

22
23

36

24

31

25-35 ft. lbs.

(34-48 Nm)

35
3
4

25

34

29
33

REF#

DESCRIPTION

QTY

27
32

ft. lbs.
30 30-40
(41-52 Nm)

REF#

26

28

DESCRIPTION

QTY

Pinion Oil Seal

20

Flanged Hex Nut

Pinion Nut

21

Flanged Hex Bolt

Pinion Bearing Cone

22

Vent Tube

Pinion Bearing Cup

23

Differential Case Half Cover

Pinion Spacer

AR

24

Flanged Hex Bolt

Pinion Bearing Spacer

25

Clutch Gear

Drain Plug

26

Shift Yoke

Oil Seal Shaft

27

Shift Spring Lever

O-Ring

28

Shift Lever

10

Carrier Half Cover

29

Shift Return Spring

11

Fill / Check Plug

30

Diff. Lock Solenoid

12

Gear-Side, Differential

31

Hex Bolt

13

Gear-Pinion, Mate, Differential

32

Differential Case Half

14

Differential Case Half Cover

33

Differential Cross-Pin

15

Differential Bearing Spacer

AR

34

Differential Roll-Pin

16

Tapered Roller Bearing

35

Pinion Spacer

AR

17

O-Ring, Housing Halves

36

Differential Bearing Spacer

AR

18

Shift Yoke Pivot Shaft

37

Differential Bearing Cup

19

Set Screw

38

Differential Bearing Cone

7.41

FINAL DRIVE

NOTES

7.42