Front Gearcase Removal; Prop Shaft Removal - Polaris Magnum 2x4 Service Manual

FINAL DRIVE
Front Gearcase
Front Gearcase Removal
NOTE: The front gearcase io.Q.u1 (pinion) shaft seal can be replaced without removing gearcase from frame.
1 . Remove prop shaft (see below)
2. Loosen pinion shaft nut set screws, top and bottom. See page 7.50.
3. Remove gearcase front cover.
4. Note depth to which seal is installed and pry out old seal.
5. Install new seal to depth of old.
6. Install front cover and torque to specification. It is not necessary to re-set backlash unless
RH
side cover of
front gear case is removed.
Front Gearcase Removal
1. Stop engine, place machine in gear and set
parking brake.
2. Loosen front wheel nuts slightly.
3. Elevate and support machine under
footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when re-
moving and installing bearings and seals.
4. Remove wheel nuts and wheels.
5. Remove cotter pin, lower ball joint nut and A-arm
from ball joint.
Prop Shaft Removal
6. Using a drift punch, remove the roll pin from prop
shaft at rear of gearcase. Slide prop shaft back
and away from front gearcase. Pull sharply
forward to remove from transmission shaft.
NOTE: If removing front gearcase, use a drift punch
to remove the roll pins from both front drive axles.
10/96 7.44
Polaris Industries Inc.