Drive And Brake Systems; Front Drive Coupler - Tracker Off-Road XTR1000 Service Manual

Drive and Brake
Systems
The following drive system components should be
inspected periodically to ensure proper operation:
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
C. Carrier bearing smooth rotation and bearing support
tight.
GENERAL INFORMATION
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assembling
with these screws, start the screws carefully into the
housing.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
 NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
Description
CV Boot Clamp Tool
Seal Puller
Hub Retaining Wrench
NOTE: Special tools are available from the Service

Department.

Front Drive Coupler

The front drive coupler is between the drive shaft and the
front differential. It is meant to serve as a weak point to
protect the front differential and transaxle from extreme
loads. It can be replaced independent from the drive shaft
and differential.
REMOVING
1. Lift and support the vehicle with a stand that allows
access to the front suspension with the vehicle off the
floor.
2. Remove both front tires. Disconnect the shocks from
the lower A-arms; then disconnect the sway bar link
on both sides.
3. Using a suitable strap, support the suspension and
shock absorbers; then secure them to the frame.
4. Remove the lower front fascia and grille. Move the
deflector out of the way to gain access to the two cap
screws that secure the subframe to the frame.
XX383
5. Remove the two cap screws that secure the steering
rack bracket to the subframe.
XX384
p/n
6. Remove and discard the "patch-lock" cap screws dif-
Common Tool
ferential to the driveshaft output flange.
Common Tool
0444-270
XX385
7. Disconnect the differential wire harness to prevent
damage.
8. While supporting the subframe from below, remove
the two cap screws and nuts from the rear of the sub-
frame.
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