Awd Front Housing Disassembly; Awd Front Housing Assembly; Awd Front Housing Installation - Polaris SPORTSMAN 400 2003 Service Manual

AWD FRONT HOUSING
DISASSEMBLY, CONT.
3. Remove output shaft assembly, large shim, and
thrust button with its small shim.
4. Clean all parts and inspect spacers for wear.
Inspect ring gear for chipped, broken, or missing
teeth.
5. Remove pinion cover and O-ring.
6. Unscrew fill plug and remove pinion shaft
assembly. Inspect pinion gear for chipped broken
or missing teeth.
NOTE: Pinion shaft assembly will not clear the fill plug
unless it is backed out.
AWD FRONT HOUSING
ASSEMBLY
1. Replace all O-rings,
components.
Bushings
2. Press pinion shaft seal into pinion cover until flush
with sealing surface.
3. Inspect pinion and output shaft bushings.
4. Inspect bearings on output and pinion shafts. To
replace, press new bearing on to shaft.
FINAL DRIVE
seals, and worn
7.17