Service Manual
Table Of Contents
- 2008 RANGER RZR SERVICE MANUAL
- GENERAL INFORMATION
- MAINTENANCE
- PERIODIC MAINTENANCE CHART
- COMPONENT INSPECTION / SERVICE LOCATIONS
- LUBRICANTS / SERVICE PRODUCTS
- MAINTENANCE REFERENCES
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- FUEL SYSTEM AND AIR INTAKE
- ENGINE
- TRANSMISSION AND GEARCASES
- COOLING SYSTEM
- FINAL DRIVE / WHEEL AND TIRE
- ELECTRICAL AND IGNITION SYSTEM
- STEERING AND SUSPENSION
- BRAKE SYSTEM
- ENGINE
- ENGINE SPECIFICATIONS
- ENGINE COOLING SYSTEM
- GENERAL ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Push Rods
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp
- Valve Seal / Spring Service (On Engine)
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Reassembly
- Valve Sealing Test
- Cylinder Removal
- Valve Lifter Removal / Inspection
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection and Honing Procedure
- Honing To Deglaze
- Cleaning the Cylinder After Honing
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Ring Installed Gap
- Starter Drive Bendix Removal / Inspection
- Flywheel / Stator Removal / Inspection
- Engine Crankcase Disassembly / Inspection
- Camshaft Inspection
- ENGINE REASSEMBLY
- ENGINE INSTALLATION
- TROUBLESHOOTING
- ELECTRONIC FUEL INJECTION
- GENERAL INFORMATION
- FUEL TANK
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
- CRANKSHAFT POSITION SENSOR (CPS)
- FUEL INJECTORS
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- GENERAL TROUBLESHOOTING
- EFI SYSTEM BREAKOUT DIAGRAMS
- Diagnostic Connector Circuit
- Malfunction Indicator Lamp (MIL) Circuit
- Fuel Injector (PTO) Circuit
- Fuel Injector (MAG) Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Engine Overheat Lamp Driver Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit
- Throttle Position Sensor (TPS) Circuit
- Fuel Pump Circuit
- BODY / STEERING / SUSPENSION
- CLUTCHING
- FINAL DRIVE
- TRANSMISSION
- BRAKES
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION
- BRAKE SYSTEM EXPLODED VIEW
- MASTER CYLINDER
- BRAKE PEDAL LEVER
- BRAKE BLEEDING / FLUID CHANGE
- FRONT BRAKE PADS
- FRONT CALIPER SERVICE
- FRONT BRAKE DISC
- REAR BRAKE PAD
- REAR CALIPER SERVICE
- REAR BRAKE DISC
- TROUBLESHOOTING
- ELECTRICAL
- General Information
- Switches / Controls
- Instrument Cluster
- Instrument Cluster Troubleshooting Tests
- All Wheel Drive Coil
- Gear Position Indicator Switch
- Speed Sensor
- Head Lights
- Tail / Brake / Work Lights
- Cooling System Schematic
- EFI Diagnostics
- Fuel Sender
- Relays
- Fuse Box Layout
- Fuses / Circuit Breaker
- Charging System
- Battery Service
- Conventional Battery
- Low Maintenance Battery
- Starting System
- Starting System Testing Flow Chart
- Electrical BreakOut Diagrams
- INDEX
- WIRE DIAGRAMS
7.31
FINAL DRIVE
7
REAR GEARCASE
Gearcase Removal
1. Drain the fluid from the rear gearcase.
2. Remove the rear drive shafts from each side of the rear
gearcase.
See “REAR DRIVE SHAFT” on page 7.24
3. Remove the exhaust pipe and exhaust silencer to allow for
gearcase removal.
4. Remove the (2) rear gearcase mount bracket fasteners and
mount bolt and remove bracket from vehicle.
NOTE: Some vehicles will require the bolt to be
removed from the receiver hitch to gain enough
clearance to remove the rear gearcase.
5. Remove the fasteners and bracket that secure the rear
gearcase to the transmission.
6. Remove the (4) fasteners and remove the rear mount from
the rear gearcase.
7. Pull the rear gearcase towards the rear of the vehicle to
disengage it from the transmission.
NOTE: If the splined coupler doesn’t slide off the
input shaft on the rear gearcase, use a screwdriver
to hold back the coupler while pulling the rear
gearcase back further to disengage it.
8. Remove the vent line and lift the rear gearcase upward and
on its side to remove it from the vehicle.
Remove
Remove
Silencer
Elbow
Header
Pipe
Pipe
Remove