Front Differential - Tracker Off-Road 800SX Service Manual

INSTALLING
1. Lubricate the O-rings on the actuator; then ensure all
mounting surfaces are clean and free of debris.
2. Gently align the actuator with the selector shaft and
slide it together onto the shaft taking care to engage
the cap screw in the slot of the front mounting tab.
MOD354A
3. While holding the actuator firmly forward, tighten
the front cap screw to hold the actuator in place; then
install but do not tighten the two remaining cap
screws.
MOD353A
4. Loosen the front cap screw; then tighten the cap
screw on the driveshaft side.
MOD352
NOTE: It is important to tighten this cap screw

while the others are loose to ensure proper seating of
the actuator.
5. Tighten the remaining cap screws; then install the
front differential; then connect the electrical plug to
the main harness; then secure the electrical plug.
6. Turn the ignition switch to the ON position and
check the operation by shifting the drive select
switch several times.

Front Differential

REMOVING
1. Remove the front hubs (see Hub/Brake Disc in this
section).
2. Remove the drain plug and drain the gear lubricant
into a drain pan; then install the plug and tighten to
45 in.-lb (5.08 N-m).
MOD126A
3. Located above the front drive actuator (A). Discon-
nect the front drive actuator connector from the main
harness.
MOD344
4. Remove the outer tie rods from the knuckle; then
remove the lower and upper ball joint cap screws
taking care not to strip the threads on the ball joint
shaft; then, using a rubber mallet, tap the end of the
axle and free it from the knuckle assembly. Repeat
for the other side. Discard lock nuts. Inspect cap
screws and replace if damaged.
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