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Chaincase Disassembly
1.
Position the vehicle on level ground. Drain the oil out of
the chaincase into a suitable container. Replace the drain
plug.
2.
Remove the right-side door panel, and exhaust silencer.
3.
Remove the chaincase cover. Un-screw the chain tensioner
bolt.
4.
Remove the cotter pin from the upper gear castle nut and
discard. Lock the parking brake, then remove the castle nut.
5.
Remove the lower gear fastener and washer. Note that
beveled side of the washer faces out.
6.
Remove the chain and upper / lower gears from the
chaincase.
7.
Remove the brake caliper from the chaincase. Secure the
caliper up and away from the chaincase.
CAUTION
Do not kink or bend the brake hose.
8.
Remove the drive belt from the clutches. Remove the
driven clutch.
9.
Raise the rear of the vehicle on a track stand. Loosen the
rear idler wheels and track tension adjusters. Slide the rear
idler shaft completely forward.
10. Remove the speedometer flange / housing from the
bulkhead.
11. Slide the driveshaft out of the chaincase towards the clutch-
side of the vehicle.
NOTE: On some models, it may be necessary to
remove the left-side console storage bucket.
12. Remove the nuts securing the chaincase to the frame.
Carefully pull the chaincase away from the jackshaft, then
out of the engine compartment.
13. To replace the seals and bearings, carefully pry out the seals
from the backside of the chaincase and discard.
14. Remove the two snap rings securing the bearings inside the
case.
15. Press on the outer race of each bearing from the backside
of the case to remove each bearing.
CAUTION
Always press on the outer race of the bearings.
16. To install the bearing, press on the bearing outer race from
the inside of the cover until fully seated. Install the snap ring
making sure it is seated in the groove.
17. Lightly coat the outer edge of each new seal with oil, then
install with the seal lips facing each bearing from the
backside of the case.
Final Drive and Brakes
18. Inspect the jackshaft seal sleeve for abnormal wear and tear.
Replace the o ring with a new part.
Chaincase Assembly
1.
Install a the jackshaft seal sleeve and a new o ring on the
jackshaft.
2.
Install the jackshaft installation tool, PN 2871296, on to the
end of the jackshaft, or wrap electrical tape over the
jackshaft splines.
3.
Carefully re-install the chaincase. Install the chaincase
fasteners and nuts. Hand-tighten the nuts so that the
chaincase can still be moved.
4.
Install the driveshaft back into the chaincase.
5.
Remove the jackshaft installation tool from the jackshaft,
then install the jackshaft alignment tool, PN 2871535, on
to the jackshaft.
6.
Torque all of the chaincase fasteners to specification using
a criss-cross pattern.
Chaincase Mounting Fasteners
28 Ft.Lbs. (38 Nm)
DO NOT OVER-TORQUE FASTENERS
7.
Remove the jackshaft alignment tool. Install the brake
caliper and torque fasteners to specification.
Brake Caliper Mounting Fasteners
19 - 21 Ft.Lbs. (26 - 28 Nm)
8.
Torque speedometer / driveshaft flange nuts and torque to
specification.
Speedometer / Driveshaft Nuts
17 Ft.Lbs. (23 Nm)
9.
Torque speedometer housing nuts to specification.
10. Lock the parking brake.
Speedometer Housing Nuts
17 Ft.Lbs. (23 Nm)
= T
= T
= T
= T
6.5
6
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