Transmission Assembly - Polaris 2004-2005 Sportsman 6x6 Service Manual

13. Use a 1/2" wrench to rotate high/reverse bell
crank and remove shift fork along with shafts.
14. Remove front drive input shaft bearing retainer
plate.
15. Remove pinion shaft assembly.
16. Remove front output shaft cover and ring gear
assembly.
17. Clean all components in a parts washer and
inspect for wear.
18. Inspect engagement dogs of gears and replace if
edges are rounded.
19. Inspect gear teeth for wear, cracks, chips or
broken teeth.
20. Remove seals from transmission case.
NOTE: New seals should be installed after the
transmission is completely assembled.
21. Inspect bearings for smooth operation. Check for
excessive play between inner and outer race.

TRANSMISSION ASSEMBLY

1. Install front output shaft cover and ring gear
assembly.
2. Torque bolts in 3 steps using a criss-cross pattern
to 18 ft. lbs. (25 Nm).
3. Install pinion shaft assembly.
4. Install retainer plate with flat side toward bearing.
5. Apply Loctitet 242 (PN 2871950) to bolts and
torque to 18 ft. lbs. (25 Nm).
6. Carefully install high/reverse shaft assembly and
gear cluster as a unit into their respective bearing
TRANSMISSION
8.7