|Required Tools and Supplies|
|T40 TORX® Socket||15mm Wrench|
|6mm Allen Socket||21mm Wrench|
|15mm Socket||Torque Wrench|
|19mm Socket||Breaker Bar|
|30mm Socket||Flat-Head Screwdriver|
|Sledgehammer||Tie Down Straps|
|Anti-Seize||Brake Caliper Fasteners|
|Shop Towels||Sway Bar Linkage Fastener|
|Compression Ring||Cotter Pin|
|Safety Glasses||Nitrile Gloves|
|Upper Bearing Carrier Fastener|
To learn more about tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RZR.
To remove and install the front half shaft on your RZR Turbo R, follow these steps:
1. Park the vehicle on a flat, level surface and ensure it is in PARK.
2. Remove the center cap from the wheel.
3. Loosen the axle nut with a 30mm socket.
4. Loosen the lug nuts with a 19mm socket with a breaker bar while the vehicle is on the ground. Do not remove them at this time.
5. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
6. Once safely elevated, remove the lug nuts and set aside.
7. Remove the wheel and set aside.
8. Remove and retain the four front fascia fasteners with a T40 TORX® socket. Set the fascia aside.
9. Remove and discard the axle nut from the front wheel assembly.
10. Lift one side of the brake line on the wheel hub and pressing the other side down to remove the line from the brake line bracket.
11. Loosen the tie rod nut on the bearing carrier with a 21mm socket.
12. Strike the tie rod nut to free the tie rod from the carrier. Tip: If the ball joint is stuck, gently tap around the tie rod bracket. Use care to avoid damaging the brake line or banjo bolt on the brake caliper.
13. Remove and retain the tie rod washer. Discard the nut.
14. Pull the tie rod end out of the bearing carrier.
15. Loosen the upper bearing carrier fastener and nut with a 15mm socket and 15mm wrench.
16. Loosen the lower shock mount fastener and nut with a 21mm socket and 21mm wrench.
17. Remove and retain the shock mount fastener.
18. Remove and retain the upper bearing carrier fastener and nut.
19. Attach a tie down strap to the front tie down point and attach the other end to the brake disc.
20. Attach another tie down strap to the tie down point and wrap the strap around the outer portion of the A-arm.
21. Lift the upper A-arm to remove the ball joint from the bearing carrier.
22. Loosen the brake disc tie down strap and pivot the wheel hub away from the vehicle.
23. Pivot the lower shock clevis behind the half shaft.
24. Pull the half shaft out from the bearing carrier.
25. Tighten the straps securing the carrier and A-arms to ease removal of the half shaft from the front gearcase.
26. With a quick, sharp jerk, remove the half shaft from the front gearcase.
27. Clean the anti-seize off the drive shaft splines using a clean, dry cloth.
28. Inspect the threads and splines on the half shaft for nicks or burrs and replace if needed.
29. Inspect the CV boots to ensure there are no cuts, wear or damage and replace if needed.
30. Remove and discard the compression ring on the drive shaft with a flat-head screwdriver.
31. Install a new compression ring into the groove on the end of the drive shaft and ensure it is fully seated.
32. Clean any old anti seize from the gearcase and hub assembly.
33. Apply new anti-seize to the inboard splines on the half shaft.
34. Align the splines on the half shaft with the gearcase and push in firmly on the shaft until the compression ring is fully engaged in the gearcase.
35. Lightly pull on the axle to ensure the compression ring is fully engaged.
36. Loosen the two straps securing the A-arm and carrier to relieve the tension on the arms. Ensure there is no tension applied to the brake line when doing this.
37. Pull the bearing carrier away while inserting the half shaft splines into the carrier.
38. Work the lower shock clevis over the half shaft and tighten the retention straps to aid in alignment.
39. Insert the half shaft splines into the bearing carrier until fully seated.
40. Reinstall the upper A-arm ball joint into the upper bearing carrier.
41. Reinstall the retained bearing carrier fastener and washer from the front and secure with the retained nut. Do not torque at this time.
42. Remove both tie down straps from the vehicle.
43. Align the lower shock clevis with the mounting holes on the lower A-arm and reinstall the retained fastener and washer from the front of the vehicle.
44. Reinstall the retained lower shock fastener, but do not torque at this time.
45. Reinstall the tie rod ball joint into the tie rod bracket on the bearing carrier.
46. Reinstall the retained tie rod washer and secure with a new nut.
47. Counter hold the tie rod ball joint stem with a 6mm Allen and 21mm socket. Torque the nut to 52 ft-lbs (70 Nm) plus 90 degrees.
48. Torque the upper bearing carrier fastener to 52 ft-lbs (70 Nm).
49. Torque the lower shock mount fastener to 133 ft-lbs (180 Nm).
50. Reinstall the brake line into the brake line bracket.
51. Inspect the brake line and ensure it is not damaged.
52. Reinstall the fascia fasteners, and torque the fasteners to 7 ft-lbs (10 Nm).
53. Install a new axle nut onto the half shaft.
54. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
55. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torqueing.
56. Once lowered, torque the lug nuts to 148 ft-lbs (200 Nm) in a crisscross pattern.
57. Torque the castle nut to 89 ft-lbs (120 Nm).
58. Push the dust cap onto the wheel and ensure it is fully seated.
59. Finally, lower the vehicle completely.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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