Transaxle - Tracker Off-Road XTR1000 Service Manual

ASSEMBLING AXLES
1. Install the inner boot with the small clamp making
sure the ends of the clamp are positioned correctly.
NOTE: The boot is positioned correctly when the

small end of the boot seats down into the recessed
groove.
2. Using the CV Boot Clamp Tool, secure the small
clamp of the inner boot.
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3. Apply grease into the bearing housing; then connect
the axle shaft into the joint.
4. Install the outer portion of the boot over the CV
joint; then install the large clamp making sure the
ends of the clamp are positioned correctly.
5. Using the CV Boot Clamp Tool, secure the clamp.
NOTE: Steps 1-5 can be used to replace the front

outboard boot, front inboard boot and rear outboard
boot.
NOTE: The rear axle inner CV joint does NOT sep-

arate. If the rear axle inner boot needs to be replaced,
the rear axle outer CV joint must be separated and
the rear axle outer boot must be removed to allow
access.

Transaxle

REPLACING SEALS
Output (Axle) Seals
NOTE: The transaxle does not need to be removed

for this procedure.
1. Support the vehicle on an appropriate stand; then
remove a rear wheel and axle.
2. Using an awl and a mallet, pry the seal from the case
taking care not to damage the seal bore.
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3. Wipe any oil or dirt from the seal area of the tran-
saxle.
4. Using an appropriate seal installer and protector,
install a new seal so it seats fully past the chamfer of
the case — approximately 1.5-2.0 mm (0.6-0.8 in.)
deep.
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Input (Driven Clutch) Seal
NOTE: The transaxle does not need to be removed

for this procedure.
1. Support the vehicle on an appropriate stand; then
remove the left rear wheel, the outer clutch cover, the
clutches, and the inner clutch cover.
2. Using an awl and a mallet, pry the seal from the case
taking care not to damage the seal bore.