Tracker Off-Road XTR1000 Service Manual page 114

7. Place the spring under the cover and install the cover.
It will only go on in one orientation. Tighten the cap
screws to 10 ft-lb (13.6 N-m).
XX422
Assembling Differential Assembly
1. Inspect the seals on the cover and case. Use the
appropriate removal and installation tools if replace-
ment is needed.
XX429
2. Inspect the differential assembly and bearings for
signs of damage or excessive wear. Replace as
needed. Use an appropriate bearing removal tool and
press to replace the bearings.
XX430
3. With the pinion gear and lock assembly in place,
carefully install the differential into the case.
4. With the shim and O-ring in place on the cover side,
carefully work the cover onto the case. Take care not
to damage the seals.
5. Using a Torx T-40 wrench and green Loctite #270,
install the eight cap screws that secure the cover to
the case. Tighten in a crisscross pattern to 22 ft-lb
(29.9 N-m).
XX416
NOTE: Grease can be applied to the O-ring for ease

of assembling.
NOTE: If a new housing is being installed, tighten

the cap screws to 28 ft-lb (38.1 N-m).
6. Using a new gasket, place the input shaft assembly
onto the gear case housing; then secure with the
existing cap screws. Tighten to 22 ft-lb (29.9 N-m).
7. Fill the differential with fluid.
 NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb (38.1 N-m).
8. Install the actuator.
XX405
INSTALLING
1. Place the differential in position on the subframe.
Lift the differential and subframe into place, making
sure the rear of the subframe falls into its proper
location. Thread the two front cap screw into place
but leave loose.
113