Front Drive Housing Seal Removal (In Frame); Front Drive Housing Seal Installation (In Frame) - Polaris Magnum 2x4 Service Manual

TRANSMISSION SERVICE
Front Drive Housing Seal Service
Front Drive Housing Seal Removal (In Frame)
1. Using a drift punch, remove roll pin from prop shaft
at front gearcase. Slide prop shaft back and away
from front gearcase. Pull sharply forward to
remove from transmission front output shaft.
2. Tightly wrap electrical tape over splines of output
shaft to protect sealing surface.
3. Pry front output housing seal out and discard.
4. Inspect the shaft and housing sealing areas for
nicks, burrs, or damage.
Front Drive Housing Seal Installation (In Frame)
1. Make sure the sealing areas on the front output
shaft and housing are clean and free of nicks,
burrs, or damage. Wrap splines of shaft tightly
with electrical tape to prevent seal damage during
installation.
2. Apply a light film of grease to shaft surface and
seal lip. Carefully slide new seal on output shaft
with spring side in - toward transmission. Take
care not to dislodge spring from seal lip.
3. Slide seal into position against output housing.
Using the Magnum crankshaft installation tool,
drive seal in until outer edge is flush with housing.
4. Remove electrical tape from shaft.
5. Lubricate prop shaft O-ring and install prop shaft.
6. Align roll pin holes on front gearcase and prop
shaft.
7. Drive new roll pin into place until flush with prop
shaft.
10/96 8.44
Polaris Industries Inc.