TRANSMISSION (4X4)
CHAPTER 8
TRANSMISSION (4X4)
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
SNORKEL / OUTPUT GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 8.16
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
TRANSMISSION EXPLODED VIEW (2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
TRANSMISSION EXPLODED VIEW (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
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8.3
TRANSMISSION (4X4)
SPECIFICATIONS
Torque Specifications
ITEM
Bell Crank Nut
Case Bolts
Differential Cover
Assembly Bolts
Differential Solenoid
Drain / Fill Plug
Gear Sector Cover
Oil Deflector Shield Screws
Output Gear Assembly
Retaining Screws
Park Brake Disc
Mounting Bolt
Snorkel Tube Locking Screw
Shift Fork Retaining Screws
Transmission Mounting Bolts
Front 5/16” Bolts
Transmission Mounting Bolts
Lower / Rear 3/8” Bolts
Vehicle Speed Sensor Bolt
TORQUE VALUE
12-18 ft. lbs.
(16-24 Nm)
25-30 ft. lbs.
(34-41 Nm)
23-27 ft. lbs.
(31-37 Nm)
23-27 ft. lbs.
(31-37 Nm)
10-14 ft. lbs.
(14-19 Nm)
8-12 ft. lbs.
(11-16 Nm)
20-30 in. lbs.
(2.3-3.4 Nm)
8-12 ft. lbs.
(11-16 Nm)
10-15 ft. lbs.
(14-20 Nm)
8-12 ft. lbs.
(11-16 Nm)
8-12 ft. lbs.
(11-16 Nm)
20 ft. lbs.
(27 Nm)
37 ft. lbs.
(50 Nm)
8-12 ft. lbs.
(11-16 Nm)
Lubrication
=
Recommended Transmission Lubricant:
AGL Plus (PN 2878068) (Quart)
Capacity: 33.8 oz. (1000 ml)
SHIFT LEVER
Removal
1.
Remove the (2) push rivets retaining the dash panel and remove the panel from the dash to access the shift lever.
2.
Remove the shift knob cover, retaining screw and shift knob from the shift lever.
Special Tools
PART NUMBER
PA-50231
2871698 (Part of 2871702 Kit)
2871699 (Part of 2871702 Kit)
2871282
TOOL DESCRIPTION
Snorkel Tool
Rear Output
Seal Driver
Rear Driveshaft
Seal Guide
Bearing Seal Driver
(50 mm)
3.
Remove grommet around shift lever from the dash.
4.
Remove clip and washer retaining the shift cable to the shift lever. Disconnect cable end from the lever.
5.
Remove the retaining ring, outer washer, and both bushings from the shift lever.
6.
Slide the shift lever off the mounting bracket and out from the frame.
Installation
1.
Repeat the steps in reverse order to install the gear shift lever.
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
8.4
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TRANSMISSION (4X4)
SHIFT CABLE
Inspection
Shift cable adjustment is necessary when symptoms include:
3.
With two open-end wrenches, loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns.
Inside Jam Nut
• Noise on deceleration
• Inability to engage a gear
• Excessive gear lash (noise)
• Gear selector is moving out of desired range
Inspect shift cable, clevis pins, and pivot bushings and replace if worn or damaged.
Outside Jam Nut
Adjustment
NOTE: The shift cable should be adjusted at the rear adjustment point located near the transmission. If adjustment is needed beyond that, remove the dash panel to access the shift cable adjustment point located underneath the shift lever.
4.
After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket.
1.
Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
5.
Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable.
6.
Use this procedure to loosen or tighten the shift linkage cable as needed.
Adjustment
Point
8
Neutral Position
2.
Locate the shift cable adjustment point at the engineto-transmission mount bracket.
9923499 - 2011 / 2012 RANGER 800 Service Manual
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8.5
TRANSMISSION (4X4)
TRANSMISSION SERVICE
General Operation
The RANGER 4x4 transmission has two traction operational modes: 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.
“Unlocked”
AWD
Differential - Lock
Differential - Unlock
When “Differential-Unlock” is selected on the switch, the rear differential becomes unlocked for tighter turns. An electrical solenoid mounted in the rear portion of the transmission actuates the shift fork. The solenoid plunger extends out to move the shift fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly. This unlocks the rear differential. The rear drive shafts are now dependent on the differential allowing for tighter turns.
When switch position is set to “Unlock”, the solenoid is powered and the plunger extends to disengage the clutch gear and unlock the differential.
When “Differential-Lock” is selected on the switch, power is removed from the electrical solenoid allowing the solenoid plunger to retract. Spring tension moves the shift fork back into place and engages the engagement dog to the side gear that is part of the planetary differential assembly. This locks the rear differential as a solid rear axle, increasing traction.
When switch position is set to “Lock”, power is removed from the solenoid and spring tension retracts the plunger to engage the clutch gear and lock the differential.
“Locked”
8.6
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TRANSMISSION (4X4)
Transmission Removal
1.
Place vehicle on a level surface and block the front wheels.
2.
Elevate the rear of the vehicle and safely support the vehicle under the rear frame area.
9.
Using a Phillips screwdriver, remove the (3) screws retaining the inner PVT cover to the engine. Using a
3/8” socket and ratchet, remove the (5) screws retaining the inner PVT cover to the transmission and remove the cover.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this procedure. Always wear eye protection.
3.
Remove the wheel nuts and washers from both rear wheels. Remove the rear wheels and set them off to the side.
4.
If internal transmission repair is required, drain the transmission lubricant.
5.
Remove the seat and side storage container to access the PVT system.
10. Using a 15mm socket, ratchet and wrench, remove the upper fastener from the rear shock on each side.
6.
Disconnect the brake switch harness located below the outer PVT cover.
7.
Using a 3/8” socket, extension and ratchet, remove the (9) screws retaining the outer PVT cover. Remove the cover from the vehicle.
8.
Remove the drive belt, drive clutch and driven clutch
(see Chapter 6 “Clutching”).
8
11. Remove the rear brake lines from the rear upper Aarm retainers.
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8.7
TRANSMISSION (4X4)
12. Using a 15mm socket, ratchet and wrench, remove the through-bolt retaining the rear upper A-arm to the bearing carrier on each side.
15. Remove the shift cable from the transmission bell crank and disconnect the gear selector switch.
Remove
Disconnect
13. Remove the rear drive shafts from each side of the transmission by pulling out sharply on each shaft.
16. Using a 3/4” open-end wrench, loosen the lower jam nut on the shift cable and remove the shift cable from the mount bracket.
Mount
Bracket
Loosen
14. Remove the exhaust springs retaining the exhaust silencer and remove the silencer from the vehicle.
17. Disconnect the rear differential solenoid.
Solenoid
8.8
18. Disconnect the vehicle harness from the vehicle speed sensor located on the right-hand side of the transmission.
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TRANSMISSION (4X4)
19. Remove the (3) fasteners retaining the parking brake mount bracket and remove the parking brake caliper as an assembly.
22. Remove the engine-to-transmission mount bracket from the vehicle.
Mount
Bracket
Mount
Bracket
20. Remove the (2) through-bolts and (2) lower engine mount nuts from the engine-to-transmission mount bracket.
23. Remove the lower transmission through-bolt.
Mount
Bracket
21. Remove the (2) rubber engine mounts from the engine.
24. Remove the rear transmission through-bolt.
8
Engine
Mounts
8.9
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TRANSMISSION (4X4)
25. Retain each rear drive shaft to the lower A-arm to keep them out of the way during transmission removal.
28. Tie the exhaust pipe to the airbox to hold it up during transmission removal. Remove airbox lid and air filter.
Tie Strap
Tie Strap
26. Using a 15mm socket and ratchet, remove the retaining nut from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle.
29. Remove lower clip and pin from the cargo box shock.
Tie the shock out of the way or completely remove it.
30. With the help of an assistant, lift up on the transmission and shift it over to the side to clear the vertical frame support.
27. Using a 1/2” socket and ratchet, remove the two fasteners that secure the stabilizer bar to the main frame on each side. Remove the stabilizer bar from the vehicle.
NOTE: The propshaft will slide off during removal.
31. With the help of an assistant, lift up on transmission and carefully move it towards the rear of the vehicle.
Remove
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TRANSMISSION (4X4)
32. Close the cargo box. With the help of an assistant, remove the transmission from the rear of the vehicle as shown.
NOTE: Removal can be aided by using your thumbs to press down on the shafts while pulling the cover up with your fingers.
Transmission Disassembly
NOTE: Refer to the exploded view at the end of this chapter as a reference.
1.
Place the transmission in Reverse before disassembly.
2.
Drain and properly dispose of the transmission lubricant (see Chapter 2).
3.
Remove the shift cable from the bellcrank (B).
4.
Remove the bellcrank nut (A) and bellcrank (B).
7.
Remove the compression spring (G).
8.
Remove the detent star (H). Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly.
9.
Remove the lockout disc (I). Note the raised edge facing outward for reassembly.
10. Remove the shift shaft (J), detent pawl (K) and the shift gears (L and M).
IMPORTANT: Note the timing marks on the shift gears
(L and M) for reassembly purposes.
8
5.
Remove the E-clip (C) that retains the gear selector switch (D) and remove the switch.
6.
Remove the sector cover bolts (E) and remove the sector cover (F).
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TRANSMISSION (4X4)
11. Remove the bolt and washer retaining the brake disc assembly to the transmission and remove the disc.
12. Remove all the transmission cover bolts. Using suitable pry bars, remove the cover using the designated pry points (indicated by the black arrows in the illustration below). Tap cover with soft face hammer to remove.
14. Remove the cam chain tensioner spring (O). Slide the cam chain tensioner shoe (P), pins (Q) and cam chain tensioner cam (N) from the assembly.
P
N
Q
O
Q
15. Remove the differential gear (R) and chain by gently prying underneath or tapping the differential gear from the opposite side until it tips toward the output gear
(S). The differential gear is connected to the shift fork and must slide backwards to clear the fork arms once the chain is removed.
CAUTION
Do not pry on case sealing surfaces.
Use only the designated pry points on the transmission.
13. Note location of chain tensioner cam (N). If fully extended, chain is worn beyond service limit and should be replaced along with the chain tensioner shoe.
R
S
16. Using a T20 Torx driver, remove the screws that secure the oil deflector (T).
N
T
8.12
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TRANSMISSION (4X4)
17. Using a T27 Torx driver, remove the screws that secure the output gear (U).
20. Place the gear cluster assembly on a clean surface for inspection.
U
18. Remove the shift drum (V) from the gearcase by moving the drum up and to the right to clear the shift shaft.
Gear Cluster Disassembly
21. Remove the bearing from the reverse shaft using a bearing puller. Slide the engagement dog off of the reverse shaft (see Figure 8-1).
V
19. Remove the output gear (U) and gear cluster assembly from the gearcase by pulling both assemblies straight up.
U
Figure 8-1
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© Copyright 2011 Polaris Sales Inc.
8.13
8
TRANSMISSION (4X4)
22. Remove the retaining ring and washer from the reverse shaft (see Figure 8-1).
23. Remove the bearing from the input shaft using a bearing puller (see Figure 8-1).
24. Remove the 33T gear and needle bearing from the reverse shaft (see Figure 8-1).
25. The reverse shaft should slide out of the silent chain to separate the assembly.
30. To disassemble the shift fork rail remove the snap ring
(W) from the end of the shift rail on either side.
W
W
26. Remove the rest of the ball bearings from each shaft.
27. Disassemble the other end of the reverse shaft.
Remove the retaining ring, washer, gear and needle bearing from the reverse shaft (see Figure 8-2).
CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may pop off causing eye or face injury.
Snorkel Shaft Removal / Disassembly
31. Using a T27 Torx driver, remove the snorkel tube locking screw located inside the gearcase.
Locking Screw
32. Remove the seal from the snorkel shaft to access the snorkel tube for removal.
Figure 8-2
28. Remove the washer, retaining ring and engagement dog from the reverse shaft (see Figure 8-2).
29. Remove the retaining ring, washer, 38T sprocket and needle bearing from reverse shaft (see Figure 8-2).
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Seal Removed
TRANSMISSION (4X4)
33. Using the Snorkel Tool (PA-50231), loosen and remove the snorkel tube and shaft assembly.
36. Remove the snap ring and shim retaining the bearing in the snorkel tube.
PA-50231
Shim
Snap Ring
37. Lightly tap on the bearing from the opposite side to remove it from the snorkel tube.
34. Remove the snap ring and shim from the snorkel shaft.
Snap Ring
38. To remove the remaining bearing on the snorkel shaft, remove the retaining ring and press the bearing off.
8
Shim
35. Use an arbor press to remove the snorkel tube from the snorkel shaft.
39. Remove all seals from the gearcase halves and clean the cases in preparation for assembly.
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TRANSMISSION (4X4)
Snorkel / Output Gear Backlash Procedure
1.
Reassemble the snorkel shaft assembly by reversing the disassembly procedure (see “Transmission
Snorkel Shaft Removal / Disassembly” in previous section).
3.
Install snorkel shaft into gearcase. Using Snorkel Tool
(PA-50231), tighten snorkel tube about 10 full rotations. Do not completely tighten snorkel tube.
PA-50231
4.
Inspect the output gear assembly and replace bearings if needed. Inspect each gear for damage, chips or abnormally worn teeth.
2.
Apply a small amount of white lithium grease on the threads of the snorkel tube.
Grease Threads
5.
Install output gear assembly. Be sure to properly mesh the snorkel shaft bevel gear with output bevel gear.
6.
Install the 4 torx screws (A) that secure the output gear assembly. Torque the screws to specification.
A
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TRANSMISSION (4X4)
= T
11. Once backlash is set, apply Loctite
®
242
™
to threads and install locking screw to secure the snorkel tube.
Output Gear Retaining Screws:
8-12 ft. lbs. (11-16 Nm)
7.
Tighten the snorkel tube until it is lightly seated using the snorkel tool (PA-50231). Turn the output shaft to prevent binding while tightening the snorkel tube.
Make sure the snorkel shaft gear and output bevel gear have ‘zero’ lash.
NOTE: It is important to have zero lash between the output gear and the snorkel shaft gear. If there is binding or excess lash, tighten or loosen the snorkel shaft until there is zero lash.
IMPORTANT: Do not overtighten the snorkel tube.
Gears should rotate freely without binding.
12. Torque the locking screw to specification.
8.
Look down into the gearcase at the snorkel locking screw hole opening to reference your starting point.
9.
Slowly rotate the snorkel tube counterclockwise while counting the number of notches passing through the hole opening as you rotate the tube. Rotate the snorkel tube to the 7th notch from the ‘seated’ position obtained in step 7.
Count 7 notches through the locking screw hole
8-12 ft. lbs.
(11-16 Nm)
= T
Snorkel Locking Screw:
8-12 ft. lbs. (11-16 Nm)
13. With the snorkel shaft properly installed, remove the
(4) Torx screws and remove the output shaft.
8
10. Check the output shaft gear backlash again by feel. If the output shaft lash appears to be too tight, rotate the snorkel shaft counterclockwise to the next notch.
8.17
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TRANSMISSION (4X4)
Transmission Assembly
1.
Assemble reverse shaft and input shaft if previously disassembled (see illustrations).
2.
Inspect the shift drum for any damage or wear. Inspect the splines of the shift drum. Replace the O-ring on the end of the shift drum and lubricate it before assembly.
8.18
3.
Stretch the silent chain on a flat surface and measure the length of 8 pitches in a minimum of three places on the chain. Replace the chain if the measurement is longer than the service limit.
= In. / mm.
Silent Chain Service Limit (8 pitch):
3.090” (7.849 cm)
4.
The shift drum, reverse shaft, input shaft, shift fork rail and output gear assembly must be installed at the same time to properly align all components.
Input Shaft Shift Fork Rail
Reverse Shaft
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TRANSMISSION (4X4)
NOTE: To ease assembly use a plastic tie strap to hold the shift forks and the shift drum together during assembly.
6.
With all the components in the correct position, install the (4) output gear assembly retaining screws. Apply
Loctite
®
242
™
to the threads of the screws. Torque the screws to specification.
Tie Strap
NOTE: If the transmission is in gear, place the transmission in Neutral.
5.
With the gearcase on it’s side, hold the gear cluster assembly and output assembly together. Carefully install each shaft into their respective recess in the gearcase.
= T
Output Gear Retaining Screws:
8-12 ft. lbs. (11-16 Nm)
7.
Install the oil deflector shield into the gearcase. Apply
Loctite
®
242
™
to the threads of the screws. Torque the screws to specification.
8
= T
Oil Deflector Retaining Screws:
20-30 in. lbs. (2.3-3.4 Nm)
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8.19
TRANSMISSION (4X4)
8.
Install the rear drive differential and drive chain, following these precautions:
• The case half rear output seal should be removed prior to differential installation, as seal damage can occur with seal installed due to the angle of entry.
• Install differential sliding geardog onto the shift fork arms at the same time the silent chain is installed.
• The differential gear bearing may be lightly tapped into place. The output seal can be installed once the assembly is in place.
• Place the spring over the front pin and hook the spring leg under the cam.
View From Left Side of Transmission
Forward
Hook Spring Leg Under Cam
Lift Spring Over Rear
Mounting Pin
• Lift the end of the spring up and over the rear pin.
The tensioner cam will lift the shoe to provide chain tension.
9.
Tensioner Installation:
NOTE: Case-halve mating may be difficult due to tensioner pressure on the silent chain during installation. Release tension at the ratcheting cam to aid case half installation. Install the tensioner spring after the case halves are mated but not yet touching.
• Assemble the tensioner cam and tensioner shoe and place them into the transmission.
• Insert the front pin through the tensioner cam and the rear pin through the tensioner shoe.
Spring Leg
10. Apply a continuous bead of Crankcase 3 Bond
Sealant (PN 2871557) to the LH gearcase mating surface and install the cover. Install and tighten the 20 screws in an even criss-cross pattern to evenly secure the cover. Torque the screws to specification.
Forward
= T
Gearcase Cover Bolts:
25-30 ft. lbs. (34-41 Nm)
Top View
8.20
Tensioner Cam
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TRANSMISSION (4X4)
11. Install all new seals into the gearcases. Use the Rear
Output Seal Driver (PN 2871698) and Rear Driveshaft
Seal Guide (PN 2871699) to install the seals into the gearcase halves (refer to the following illustration to identify the seals needing replacement).
13. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T) into the bushing pocket on the left side. Align the timing marks on the gears as shown.
2871698
2871699
Timing Marks
Reverse Gear Shown
14. Install the lockout disc onto the shift drum shaft. Be sure to install the lockout disc with the raised edge facing outward.
Lockout Disc
12. Thoroughly clean the shift shaft housing. Be sure the
transmission is in Reverse prior to reassembly.
15. Install the detent star onto the shift drum shaft. Be sure to install the detent star with the raised edge facing outward.
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Detent Star
8.21
TRANSMISSION (4X4)
16. Install the detent pawl onto the shift shaft and carefully install the compression spring.
19. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut and torque to specification.
Detent Pawl
Spring
= T
Bellcrank Nut:
12-18 ft. lbs. (16-24 Nm)
20. Install the transmission gear selector switch and secure the switch with the retaining ring.
21. Install the brake disc assembly onto the output shaft.
Apply Loctite
®
262
™
or 2760
™
to the mounting bolt threads and torque the bolt to specification.
17. Install a new O-ring on each shift shaft. Apply a small amount of white lithium grease on the O-rings, shift shafts and component contact surfaces prior to installing the sector cover.
O-Rings
18. Apply Crankcase Sealant (3-Bond) (PN 2871557) onto the cover and transmission case mating surface.
Install the sector cover and torque the bolts to specification.
= T
Sector Cover Bolts:
8-12 ft. lbs. (11-16 Nm)
= T
Park Brake Disc Mounting Bolt:
10-15 ft. lbs. (14-20 Nm)
8.22
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TRANSMISSION (4X4)
Transmission Installation
1.
If transmission lubricant was drained, fill the transmission with the specified amount of Polaris
AGL Plus prior to installation.
= T
Transmission Mounting Fastener Torque:
Front 5/16” Bolts: 20 ft. lbs. (27 Nm)
Lower / Rear 3/8” Bolts: 37 ft. lbs. (50 Nm)
=
Recommended Transmission Lubricant:
AGL Plus (PN 2878068) (Quart)
9.
Install the parking brake caliper assembly and torque the mount bracket fasteners to specification.
= T
Capacity: 33.8 oz. (1000 ml)
2.
4.
Apply Polaris Premium All Season Grease (PN
2871423) to splines of front output shaft.
Install the engine-to-transmission mount bracket.
Parking Brake Caliper to Mount Bracket:
18 ft. lbs. (24 Nm)
Mount Bracket to Transmission:
40 ft. lbs. (54 Nm)
3.
With the help of an assistant, position the transmission into the frame from the rear of the vehicle. Align the output shaft and propshaft splines while positioning the transmission to allow the shafts to slide together.
10. Connect electrical harnesses to the rear diff solenoid, gear selector switch and vehicle speed sensor.
11. Remove the tie straps retaining each drive shaft and the one retaining the exhaust pipe to the airbox.
Reinstall the air filter and airbox lid.
5.
Install the (2) rubber engine mounts into the engine crankcase.
12. Properly route the transmission vent line. Be sure vent line is not kinked or pinched.
6.
Position the engine-to-transmission mount bracket and install the (2) through-bolts and (2) lower engine mount nuts loosely.
13. Install the rear cargo box shock.
14. Install the stabilizer bar to the frame and to each stabilizer linkage. Torque fasteners to specification.
7.
Install the lower and rear transmission through-bolts.
= T
IMPORTANT: Be sure the brake line is clear of the lower through-bolt upon installation.
Lower
Through-Bolt
Stabilizer Bar Retaining Bolts:
Stabilizer Linkage Rubber Bushing Nuts:
17 ft. lbs. (24 Nm)
15. Apply anti-seize to the splines of each rear drive shaft and insert them into the transmission.
8
8.
Torque all transmission mount fasteners to specification.
Apply Anti-Seize
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
8.23
TRANSMISSION (4X4)
16. Attach the rear upper A-arms to the bearing carrier on each side and torque the fasteners to specification.
= T
Rear Upper A-Arm to Bearing Carrier Bolts:
30 ft. lbs. (41 Nm)
17. Place the rear brake line into the retainer located on each rear upper A-arm.
21. If both adjustment jam nuts were moved, adjust the shift cable (see “Shift Cable - Adjustment”).
22. Install the exhaust silencer and (2) retaining springs.
23. Install the inner PVT cover and torque the (8) screws to specification (see Chapter 6).
24. Install the drive clutch, driven clutch and drive belt.
Torque the clutch retaining bolts to specification (see
Chapter 6).
NOTE: Align clutches as outlined in Chapter 6.
25. Install the outer PVT cover and (9) screws. Torque the screws to specification (see Chapter 6).
26. Install the brake switch harness below the outer PVT cover.
27. Install the rear wheels, washers and wheel nuts.
Torque the wheel nuts to specification.
= T
Wheel Nuts:
Steel Wheels: 35 ft. lbs. (47 Nm)
Aluminum Wheels: 30 ft. lbs. (41 Nm) + 90°
18. Attach the rear shocks to the frame and torque the upper fasteners to specification.
= T
Rear Upper Shock Bolts:
30 ft. lbs. (41 Nm)
19. Install the shift cable onto the mount bracket.
20. Install the shift cable onto the transmission bell crank end and secure with the outer washer and clip.
28. Carefully lower the vehicle to the ground and reinstall the side storage container and seat.
8.24
Washer Clip
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is encountered.
• Shift cable adjustment/condition
• Idle speed (throttle cable routing)
• PVT clutch alignment
• Transmission lubricant type/quality
• Drive belt deflection (where applicable)
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission components
NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting the shift cable end from the transmission bellcrank. Manually select each gear range at the transmission bellcrank,
and test ride vehicle. If it functions properly, the problem is outside the transmission.
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear
(rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
TRANSMISSION (4X4)
8
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
8.25
TRANSMISSION (4X4)
TRANSMISSION EXPLODED VIEW (2011)
RANGER XP/HD 800 (PN 1332898); RANGER CREW 800 (PN 1332872)
242
®
23-27 ft. lbs.
(31-37 Nm)
25-30 ft. lbs.
(34-41 Nm)
10-15 ft. lbs.
(14-20 Nm)
262
®
8-12 ft. lbs.
(11-16 Nm)
242
®
242
®
20-30 in. lbs.
(2.3-3.4 Nm)
8-12 ft. lbs.
(11-16 Nm)
242
®
10-14 ft. lbs.
(14-19 Nm)
23-27 ft. lbs.
(31-37 Nm)
12-18 ft. lbs.
(16-24 Nm)
8.26
8-12 ft. lbs.
(11-16 Nm)
8-12 ft. lbs.
(11-16 Nm)
242
®
8-12 ft. lbs.
(11-16 Nm)
242
®
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
FOR REASSEMBLY
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
Apply Loctite
®
to the bolt threads.
TRANSMISSION (4X4)
Exploded View, Continued
38.
39.
40.
41.
42.
33.
34.
35.
36.
37.
43.
44.
45.
46.
47.
48.
49.
27.
28.
29.
30.
31.
21.
22.
23.
25.
26.
16.
17.
18.
19.
20.
11.
12.
13.
14.
15.
4.
5.
6.
7.
8.
9.
10.
Ref.
Qty.
1.
20
Description
Screw, Self Tapping Hex
2.
3.
2 Seal, Triple Lip
1 Cover, LH
2
1
1
2
Bearing, Ball
Silent Chain
Case, RH
1 Bearing, Ball
1 Sprocket, 19T
1 Oil Deflector
Screw, Self Tapping Torx
1
2
1
1
Output Gear, 91T
1 Retaining Ring
6 Screw, Self Tapping Hex
1 Bearing Cover, Center Drive
Retaining Ring
Shim
1 Bearing, Ball
1 Pinion, 13T Center Drive
1 Retaining Ring
Thrust Washer
1 Gear, 36T Spur (XP/HD); Gear, 41T Spur (CREW) 71.
1 Bearing, Needle
1 Washer
2 Engagement Dog, 6-Face
2 Retaining Ring
2 Thrust Washer
1 Sprocket, 38T 6-Face
1 Reverse Shaft, 26T
1 Gear, 33T 6-Face
1 Shift Collar
2 Bearing, Ball
1 Seal, Triple Lip
3 Bearing, Ball
1 Input Shaft, 35T (XP/HD); Input Shaft, 31T (CREW) 84.
1 Silent Chain
1 Compression Spring
2 Shift Fork
2 Compression Spring
1 Rail, Shift Shaft
2 Pin
1 Torsion Spring
1 Cam, Chain Tensioner
1 Shoe, Chain Tensioner
1 Shift Drum
1 Gear, Sector 31T
1 Shift Shaft
1 O-Ring
72.
73.
74.
75.
81.
82.
83.
85.
94.
99
100.
101.
102.
103.
104.
76.
77.
78.
79.
80.
86.
87.
88.
89.
93.
65.
66.
67.
68.
69.
60.
61.
62.
63.
64.
53.
54.
55.
56.
57.
58.
59.
Ref.
Qty.
50.
1
51.
52.
1
1
1
1
1
1
1
1
1
7
1
2
1
1
1
1
1
1
1
1
6
1
2
2
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
Description
Detent Pawl
Compression Spring, Detent
Cover, Sector
Bellcrank, Shift Drum
Lock Nut
Rotary Switch, 6-Pin
Retaining Ring
Gear, Sector 16T
Drain Plug, Magnetic
Detent Star
O-Ring
Gear, 13T Snorkel
Bearing, Ball
Retaining Ring
Snorkel Tube
Screw, Torx
Shim
Retaining Ring
Seal, Triple Lip
Seal, Triple Lip
Dowel Pin
Fill Plug
Compression Spring
Retaining Ring
Washer, Cup
Retaining Ring
Shim
Engagement Dog
Torsion Spring
Fork, Pivot Shift, Rear Diff
Side Gear, 36T
Carrier Assembly
Side Gear, 36T, Disconnect
Gear Assembly
Dowel Pin
Cover
Screw
Solenoid
Washer, Fender
Bearing, Needle
Lockout Disc
Vehicle Speed Sensor
O-Ring
Brake Disc/Hub Assembly
Washer, Fender
Screw
Vent Tube
8
8.27
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
TRANSMISSION (4X4)
TRANSMISSION EXPLODED VIEW (2012)
RANGER XP/HD 800 (PN 1332961); RANGER CREW 800 (PN 1332977)
25-30 ft. lbs.
(34-41 Nm)
242
®
23-27 ft. lbs.
(31-37 Nm)
10-15 ft. lbs.
(14-20 Nm)
262
®
8-12 ft. lbs.
(11-16 Nm)
242
®
20-30 in. lbs.
(2.3-3.4 Nm)
242
®
8-12 ft. lbs.
(11-16 Nm)
242
®
10-14 ft. lbs.
(14-19 Nm)
23-27 ft. lbs.
(31-37 Nm)
242
®
8-12 ft. lbs.
(11-16 Nm)
10-14 ft. lbs.
(14-19 Nm)
8-12 ft. lbs.
(11-16 Nm)
242
®
12-18 ft. lbs.
(16-24 Nm)
8.28
8-12 ft. lbs.
(11-16 Nm)
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
FOR REASSEMBLY
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
Apply Loctite
®
to the bolt threads.
TRANSMISSION (4X4)
Exploded View, Continued
38.
39.
40.
41.
42.
33.
34.
35.
36.
37.
43.
44.
45.
46.
47.
48.
28.
29.
30.
31.
32.
23.
24.
25.
26.
27.
18.
19.
20.
21.
22.
13.
14.
15.
16.
17.
6.
7.
8.
9.
10.
11.
12.
Ref.
Qty.
1.
2 Fill Plug
2.
3.
4.
5.
1
2
7
20
Drain Plug, Magnetic
Screw, Self Tapping Torx
Screw, Torx
Description
Screw, Self Tapping Hex
6
6
1
2
Screw, Self Tapping Hex
Screw
Screw
1 Lock Nut
1 Washer
2 Washer, Fender
Washer, Cup
1
2
1
1
Washer, Fender
2 Pin
2 Dowel Pin
6 Dowel Pin
Retaining Ring, External
Snap Ring
2 Retaining Ring
2 Retaining Ring
1 Retaining Ring
Retaining Ring, External
1
1
1
1
1
1
3
1
2
2
2
2
1
Retaining Ring, Internal
2 Retaining Ring, External
1 Retaining Ring, External
Thrust Washer
Shim
Shim
1 Shim
2 Thrust Washer
Bearing, Needle
Bearing, Ball
Bearing, Ball
2 Bearing, Needle
1 Bearing, Ball
Bearing, Ball
Bearing, Ball
Bearing, Ball
1 Torsion Spring
1 Compression Spring
Compression Spring
Compression Spring
Torsion Spring
1 Compression Spring
1 Snorkel Tube
1 Cover, Sector
1 Cover, LH
1 Case, RH
87.
88.
92.
93.
94.
81.
82.
84.
85.
86.
95.
96.
97.
98.
100.
76.
77.
78.
79.
80.
71.
72.
73.
74.
75.
66.
67.
68.
69.
70.
61.
62.
63.
64.
65.
54.
55.
56.
57.
58.
59.
60.
Ref.
Qty.
49.
1
50.
51.
52.
53.
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
6
1
1
1
1
1
1
1
Description
Shift Drum
Gear, Sector 16T
Gear, Sector 31T
Detent Pawl
Detent Star
Lockout Disc
Input Shaft, 31T (CREW); Input Shaft, 35T (XP/HD)
Gear, Snorkel, 13T
Gear, Output, 91T
Reverse Shaft, 26T
Pinion, Center Drive, 13T
Shoe, Chain Tensioner
Cam, Chain Tensioner
Bellcrank, Shift Drum
Shift Shaft
Shift Collar
Rail, Shift Shaft
Shift Fork
Vent Tube
Fork, Pivot Shift, Rear Diff
Gear, 41T (CREW); Gear, 36T (XP/HD)
Sprocket, 38T, 6-Face
Gear, 33T, 6-Face
Engagement Dog, 6-Face
Sprocket, 19T
Engagement Dog
Engagement Dog, Low, 6-Face
Side Gear, 36T, Disconnect
Side Gear, 36T
Planet Gear Assembly
Cover
Carrier Assembly
Brake Disc/Hub Assembly
Bearing Cover, Center Drive
Oil Deflector
Chain
Silent Chain
Solenoid
Rotary Switch, 2-Pin
O-Ring
O-Ring
O-Ring
Seal, Triple Lip
Seal, Triple Lip
Seal, Triple Lip
Seal, Dual Lip
Speed Sensor
8
8.29
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
TRANSMISSION (4X4)
NOTES
8.30
9923499 - 2011 / 2012 RANGER 800 Service Manual
© Copyright 2011 Polaris Sales Inc.
