| Required Tools and Supplies | |
| 18mm Socket | Ratchet |
| 19mm Socket | Torque Wrench |
| 21mm Socket | Breaker Bar |
| 18mm Wrench | Flat Head Screwdriver |
| 21mm Wrench | Rivet Tool |
| Drill | Rivet |
| 3/16-Inch Drill Bit | Shock Fastener |
| Shop Rags | Shock Nut |
| Nitrile Gloves | Safety Glasses |
| Bearing Carrier Fastener (part number 7521335-180) | Lower Control Arm Nuts (part number 7548031) |
| Bearing Carrier Nut (part number 7548031) | Lower Control Arm Fasteners (part number 7521335-130) |
| Stabilizer Bar Link Fastener (part number 7521334-70) | Stabilizer Bar Link Nut (part number 7548030) |
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 rear 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 a 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. With light pressure and high rotation speed, drill the brake line rivet out of the upper control arm to free the arm from the brake line. Note: Use care to avoid damaging the brake line during this process.
4. Remove the lower shock fastener, washer and nut with a 18mm socket and 18mm wrench. Discard the fastener and nut.
5. Remove and discard the lower bearing carrier fastener, nut and washer with a 21mm socket and 21mm wrench.
6. Remove the stabilizer bar link fastener, nut and washer with a 18mm socket and 18mm wrench. Discard the fastener and nut. Tip: Lift up on the bearing carrier to ease tension on the link fastener removal.
7. Support the lower control arm with a wire hanger, rope or retention strap to prevent the arm from swinging down.
8. Remove and discard the rear most control arm nut with a 21mm socket and 21mm wrench. Tip: Leaving the fastener in will help keep the arm in place during removal of the front most fasteners.
9. Remove the front most control arm fastener, washer and nut.
10. Pull out rearmost fastener and remove the arm from the vehicle.
11. If reusing the control arm, thoroughly clean with a shop rag before reinstalling.
12. 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.
13. Inspect the bearing carrier bushings and pivot tube for wear or damage and replace as necessary. Note: When reinstalling the bushings, ensure the tapered side is inserted into the carrier. Also ensure the bushings are fully installed inside the carrier before installing the pivot seals.
14. Align the lower control arm with the mounting holes and install new fasteners with the retained washers from the rear of the vehicle. Secure with new nuts.
15. Align the stabilizer bar link with the arm and install a new fastener from the rear of the vehicle. Secure with the retained washer and a new nut.
16. Align the arm with the bearing carrier and install a new fastener from the rear of the vehicle. Secure with the retained washer and a new nut.
17. Align the shock with the shock mount and install a new fastener and the retained washer from the rear of the vehicle. Secure with a new nut.
18. Torque the control arm fasteners to 148 ft-lbs (200 Nm).
19. Torque the shock mount fastener to 88 ft-lbs (120 Nm).
20. Torque the bearing carrier fastener to 148 ft-lbs (200 Nm).
21. Torque the stabilizer bar link fastener to 88 ft-lbs (120 Nm).
22. Align the brake line retainers with their mounting holes and secure with new rivets. Ensure the brake line is seated over top of the arm and behind the shock mount before securing.
23. Install the wheel on the vehicle and tighten the lug nuts until fully seated.
24. Once installed safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
25. Once lowered, torque the lug nuts to 20 ft-lbs (163 Nm) in a crisscross pattern.
26. 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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