Gearcase Removal; Gearcase Disassembly - Polaris MS4000 Service And Owner's Manual

Gearcase Removal

1. Follow "Rear Drive Shaft Removal" procedure to remove
the rear drive shafts from each side of the rear differential.
2. Disconnect the differential solenoid 2-wire harness.
3. Completely drain the lubricant from the rear gearcase
Drain Plug
4. Remove the four bolts that secure the rear gearcase to the
frame.
5. Remove the (3) fasteners retaining the parking brake
caliper bracket to the rear gearcase and carefully pull the
rear gear case assembly from the frame. Allow the rear
propshaft to slide off of the rear gearcase shaft.
Bracket
(3)
Propshaft
Remove the (2)
fasteners from
each side.

Gearcase Disassembly

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.
1. Remove the differential solenoid from the gearcase cover
if servicing the solenoid, shift lever, shift lever spring, or
shift yoke. If none of these items are being serviced, the
solenoid can remain installed in the gearcase cover.
2. Remove the (7) bolts that secure the cover to the housing.
Remove Cover Bolts
FINAL DRIVE
7
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