Type Iii Transmission Assembly - Polaris Magnum 2x4 Service Manual

Disassembly (Typical), Cant.
12.
Clean all components in a parts washer and inspect
for wear.
13. Inspect engagement dogs of gears and replace if
edges are rounded.
14. Inspect gear teeth for wear, cracks, chips or broken
teeth.
15.
Remove seals from transmission case.
NOTE:
New seals should be installed after the transmis-
sion is completely assembled.
16.
Inspect bearings for smooth operation. Check for
excessive play between inner and outer race.
Assembly (Typical)
1 . Carefully install high/reverse shaft assembly and
gear cluster (removed in step
11)
as a unit into their
respective bearing case areas. Make sure input shaft
clears oil deflector. Tap with a soft face hammer to
seat shaft assemblies.
NOTE:
Make sure high/reverse shift shaft pin is properly
positioned within spring retainers.
2.
Seat the shafts and shift the assembly into neutral
position.
NOTE:
The assembly must be in neutral at this time to
complete reassembly.
3.
Install the output shaft and gear assembly into the
gear case.
4.
Install engagement dog on low range shift shaft.
NOTE:
Dogs should face toward the mating gear.
5. Install low shift shaft assembly aligning shaft pin with
spring; engagement dog splines with the sliding gear
shaft splines; and shift shaft to the gearcase.
See III. 1.
6.
Install large I.
D.
washer on sliding gear shaft.
7. Install low gear on shaft with engagement dogs
inward. See photo at right.
8. Lubricate and install needle bearing into gear.
9.
Install smaller 1.0. washer and bearing.
NOTE:
The bearing should be flush with the shaft when
seated correctly.
10. Prior to reinstalling the cover make sure the mating
cover surfaces are clean and dry. Apply Loctite
515
or
518
to mating surfaces.
11.
Reinstall cover and torque bolts to
12
ft. Ibs.
(1.66
kg-m).
12.
Install transmission and fill with Polaris Premium
Synthetic Gear Case Lubricant.
Polaris Industries Inc. 8.15
III. 1
TRANSMISSION SERVICE
Type III, EZ-Shift Transmission
7/96