Final Drive

FINAL DRIVE

Gearcase Removal

1.

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

2.

Elevate front of vehicle and safely support machine under the frame area.

CAUTION

Disassembly / Inspection

1.

Drain and properly dispose of used lubricant.

Remove any metal particles from the drain plug magnet.

2.

Remove the (5) screws retaining the outer cover assembly.

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this service procedure.

3.

Remove both front drive shafts from the front gearcase (see “FRONT DRIVE SHAFT - Removal”).

4.

Remove the front propshaft from the front gearcase

(see “FRONT PROPSHAFT - Removal”).

5.

Remove LH wheel well panel and disconnect AWD wire harness. Cut plastic tie strap to free the connector end from the main harness to allow gearcase removal.

6.

Remove the (4) bolts securing the bottom of the gearcase to the skid plate frame.

3.

Remove the output cover assembly from the gearcase.

NOTE: Thrust bushing located between the two output hubs is pressed into assembly.

4.

Remove the RH output hub assembly from the outer cover plate assembly.

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7.

Remove the vent line from the gearcase.

8.

Remove gearcase from front left-hand wheel well area and pull it out between upper and lower A-arms.

Cover

Plate

Output Hub

Assembly

5.

Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged.

6.

Remove and inspect the armature plate. Refer to

“AWD Diagnosis” for detailed inspection process.

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© Copyright 2011 Polaris Sales Inc.

FINAL DRIVE

7.

Remove the torsion spring retainer and torsion spring from the top of the ring gear.

Spring Retainer

10. Remove the roll cage assembly and rollers from the clutch housing. Use a shop towel to cover the housing in order to retain all the rollers.

NOTE: Rollers are spring loaded. Take care not to allow them to fall out or lose them upon removal of the roll cage.

11. Thoroughly clean all parts and inspect the rollers (A) for nicks and scratches. The rollers must slide up and down and in and out freely within the roll cage (B) sliding surfaces and H-springs.

C

Torsion Spring

B

8.

Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing.

Remove as an assembly

A

IMPORTANT: Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit.

12. Inspect clutch housing ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth.

9.

Remove LH output hub. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged.

13. Inspect the roll cage assembly (B) sliding surfaces and H-springs. The sliding surfaces must be clean and free of nicks, burrs or scratches. If damaged, replace the roll cage assembly.

H-Spring B

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9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

FINAL DRIVE

14. Inspect both output hub assemblies. Inspect the bearings and replace if needed.

17. Inspect the magnetic coil (D) in the outer cover plate assembly. Inspect the backlash pad (E) for excessive wear.

Bearing Thrust

Bearing

E

D

Spacer

Roller

Surface

15. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage.

NOTE: See “AWD DIAGNOSIS” in this section for more details on the coil.

16. Inspect the armature plate for a consistent wear pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation.

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 “Setting Ring Gear

Backlash” procedure later in this chapter for details on backlash setting.

18. Remove the bolts retaining the input shaft cover and pinion gear assembly.

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NOTE: See “AWD DIAGNOSIS” in this section for more details.

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

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