Awd Front Drive Axle Installation - Polaris SPORTSMAN 400 2003 Service Manual

1. Loosen front wheel nuts slightly.
2. Elevate and support
footrest/frame area with front wheels elevated.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing and installing drive axles or component
parts.
3. Remove wheel nuts and wheels.
4. Remove hub cap.
5. Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake
hose. Use wire to hang the caliper to prevent
possible damage to the brake line.
6. Place a catch pan beneath the front hub and
remove the hub cap.
7. Remove cotter pin and nut.
8. Remove hub, bearings, hilliard assembly, and
armature plat
machine under
9. Remove cotter pin and nut from lower A-arm ball
10. Using Roll Pin Remover (PN 2872608), remove
11. Remove the spindle and axle assembly from the
AWD FRONT DRIVE AXLE
INSTALLATION
1. Install spring washer and drive shaft. Align hole in
2. Install new seal in strut casting. Refer to Page
joint. Remove lower A-arm from ball joint.
the roll pin at front housing.
Roller Pin Removal Tool (PN 2872608)
strut casting bearing by pulling the strut outward
as shown. Drive out the old seal, taking care not
to damage the tapered roller bearing. Install the
new seal until it bottoms against the shoulder in
the strut casting.
U-joint yoke with hole in eccentric shaft, and
install new roll pin.
7.13.
FINAL DRIVE
7.9