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2024 Polaris XPEDITION XP and ADV Front Lower A-Arm Removal and Installation

Required Tools and Supplies

  • 6mm Allen Socket
  • 18mm Socket
  • 19mm Socket
  • 18mm Wrench
  • Ratchet
  • Torque Wrench
  • Breaker Bar
  • Soft Face Hammer
  • Flat Head Screwdriver
  • Stabilizer Bar Link Nut (part number 7548030)
  • Lower Ball Joint Nut (part number 7547334)
  • Lower Control Arm Nuts (2) (part number 7548030)
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris XPEDITION.

To remove and install the front lower control arm on your Polaris XPEDITION XP or ADV, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key. 

2. Remove the wheel from the vehicle. 

  • Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground, but do not remove them at this time.
  • Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
  • Once safely elevated, remove the lug nuts and set aside. 
  • Remove the wheel and set aside. 

3. Remove the lower stabilizer bar link nut and washer and discard the nut with a 18mm socket and 18mm wrench. Leave the fastener in until the arm can be lowered and the fastener can clear the drive shaft.

4. Remove and discard the lower ball joint nut with a 18mm socket.

5. Tap the bearing carrier on the indicator mark with a soft face hammer to loosen the ball joint end. If necessary, use a ball joint separator to separate the ball joint from the carrier.

6. Remove the lower control arm fasteners, washers and nuts with a 18mm socket and 18mm wrench, and discard the fasteners and nuts.

7. Lower the arm and remove the stabilizer bar link fastener.

8. Pivot the stabilizer bar link up and out of the way to create extra clearance. Tip: Pushing inward on the control arm assembly can create more clearance to remove the sway bar from the arm.

9. Pull the bottom of the bearing carrier out while pivoting the rear of the arm up to remove the front portion of the arm from the mount.

10. Pivot the rear portion of the arm down and out of the mount.

11. Lift the ball joint out of the bearing carrier to remove the arm from the vehicle.

12. If reusing the control arm, thoroughly clean with a shop rag before reinstalling.

13. Inspect the control arm bushings and pivot tube for wear or damage and replace as needed. Note: When reinstalling the bushings, ensure the tapered side is inserted into the arm. Also, ensure the control arm bushings are fully installed inside the arm before installing the pivot seals.

14. Inspect the ball joint and ball joint boot for wear, tears or damage and replace if necessary.

15. Before reinstalling, inspect the stabilizer bar link bushing for wear or damage and replace if necessary.

16. Insert the ball joint into the bearing carrier.

17. Pull the bottom of the carrier out to pivot the control arm in and seat the inside the mounting bracket.

18. Reinstall the stabilizer bar link fastener from the front of the vehicle.

19. Reinstall the retained control arm fasteners and washers from the front of the vehicle and secure with new nuts.

20. Install the retained washer and a new nut onto the stabilizer bar link fastener.

21. Install a new nut on the lower ball joint end and counter-holding the ball joint end to tighten the nut with a 6mm Allen socket and 18mm wrench.

22. Torque the control arm fasteners to 148 ft-lbs (200 Nm).

23. Torque the ball joint nut to 29 ft-lbs (40 Nm) + 90 degrees. Tip: Turning the wheels to full left will aid in achieving full torque.

24. Torque the stabilizer bar link fastener to 88 ft-lbs (120 Nm).

25. Install the wheel on the vehicle and tighten the lug nuts until fully seated.

26. Once installed, safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing. 

27. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern. 

28. 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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© 2023 Polaris Industries Inc.

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