Inner Plunging Joint / Boot Replacement - Polaris MS4000 Service And Owner's Manual

FINAL DRIVE

Inner Plunging Joint / Boot Replacement

1. Remove the front drive shaft from the vehicle (see
"FRONT DRIVE SHAFT - Removal").
2. Remove and discard the boot clamps.
CV Boot Clamp Pliers
Earless Type: 8700226
3. Remove the large end of the boot from the plunging joint
and slide the boot back.
4. Use a soft-faced hammer or brass drift to separate the
plunging joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the
inner race of the joint only.
5. Make sure the circlip remains on the shaft and not left in
the joint. Discard the circlip.
6. Remove the boot from the drive shaft.
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7. Thoroughly clean the joint with an appropriate solvent and
dry the joint to prevent any residual solvent from being left
in the joint upon reassembly.
8. Visually inspect the joint by tilting the inner race to one side
to expose each ball. Severe pitting, galling, play between
the ball and its cage window, any cracking or damage to the
cage, pitting or galling or chips in raceways call for joint
replacement.
9. Clean the splines on the end of the shaft and apply a light
coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) onto
the drive shaft and position the boot in it's groove machined
in the shaft.
11. Install a NEW circlip on the end of the shaft.
7.10
CAUTION
12. Grease the joint with the special CV joint grease provided
in the boot replacement kit. Fill the cavity behind the balls
and the splined hole in the joint's inner race. Pack the ball
tracks and outer face flush with grease.
remaining grease into the boot.
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
NOTE: The amount of grease that's provided is pre-
measured, so use all the grease.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint Capacity: 150g
13. Fully compress the joint and push the drive shaft firmly into
the inner race.
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the drive shaft
until it locks into place.
16. Pull on the joint to make sure it is securely locked into place.
17. Remove excess grease from the plunging joint's external
surfaces and place the excess grease in the boot.
18. Pull the boot over the joint and position the boot lips into
the grooves on the joint housing and shaft. Make sure the
boot is not dimpled or collapsed.
19. Install and secure the small clamp on the boot using the
"earless" clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
Place any
CAUTION