Service Manual

8.43
FINAL DRIVE
8
Gearcase Installation
1. Install the coupler onto the pinion shaft splines.
2. Install the locking washer(s) and retaining nut.
3. Torque the retaining nut to specification.
4. Install the rear gearcase by reversing the “Gearcase
Removal” procedure at the beginning of this section. Refer
to the following steps for torque specifications.
5. Install the gearcase through-bolt mounting fasteners and
torque to specification.
NOTE: Use the longer bolts (150 mm) in the top and
the shorter bolts (125 mm) in the bottom.
6. Install the right rear drive shaft and the upper A-arm onto
the bearing carrier. Torque through-bolt fastener to
specification.
7. Install the cone washers (dome facing retaining nut) and
right rear hub retaining nut. Torque to specification and
install a new cotter pin.
8. Install the left rear drive shaft and suspension assembly.
Torque the upper and lower A-arms to specification.
9. Install the left rear brake caliper and brake line retainer.
Torque brake caliper mounting bolts to specification.
10. Install the rear upper shock through-bolts. Torque bolts to
specification.
11. Install the rear stabilizer bar onto the linkage rods. Torque
the linkage retaining nuts to specification.
12. Install the rear propshaft and torque bolts to specification.
13. Reassemble the PVT system (see Chapter 7 “PVT
SYSTEM SERVICE - Assembly”).
14. Install the rear wheels and torque wheel nuts to
specification (see Page 8.2).
15. Add Polaris ATV Angle Drive Fluid to rear gearcase (see
Chapter 2). Torque drain and fill plugs to specification.
= T
Coupler Retaining Nut Torque:
90-110 ft. lbs. (122-149 Nm)
= T
Gearcase Mounting Fasteners:
40 ft. lbs. (54 Nm)
= T
Rear Upper A-arm to Bearing Carrier:
40 ft. lbs. (54 Nm)
= T
Rear Hub Retaining Nut:
80 ft. lbs. (108 Nm)
= T
Rear Upper & Lower A-arms to Frame:
45 ft. lbs. (61 Nm)
= T
Brake Caliper Mounting Bolts:
37 ft. lbs. (50 Nm)
= T
Rear Upper Shock Bolts:
37 ft. lbs. (50 Nm)
= T
Stabilizer Bar Linkage Retaining Nuts:
17 ft. lbs. (23 Nm)
= T
Rear Propshaft Bolts:
18 ft. lbs. (24 Nm)
=
Rear Gearcase Capacity:
7.1 fl. oz. (210 ml)
or to bottom of fill plug hole threads
See Chapter 2 “Maintenance”
= T
Drain / Fill Plug:
10-14 ft. lbs. (14-19 Nm)