Required Tools and Supplies | |
| 15mm Socket | 18mm Socket |
| 19mm Socket | 15mm Wrench |
| Ratchet | Torque Wrench |
| Breaker Bar | Soft Face Hammer |
| Flat-Head Screwdriver | Needle Nose Pliers |
| Wire Hanger, Rope or Retention Strap | Anti-Seize |
| Brake Caliper Mounting Fasteners | Upper Ball Joint Nut |
| Lower Ball Joint Nut | Tie Rod Nut |
| Cotter Pin | Eye Protection |
| Nitrile Gloves | Shop Towels |
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RANGER.
To remove and install the front drive shaft on your RANGER XD 1500, 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.
3. Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground but do not remove at this time.
4. Safely elevate the vehicle. Reference your Owner's Manual for proper lifting techniques.
5. Remove the wheel nuts and the front wheel and set aside.
6. Remove the cotter pin with a needle nose pliers. Then, with the aid of an assistant, have them press the brakes and firmly hold the steering wheel while loosening the castle nut with a 30mm socket. Remove the nut and cone washer from the front wheel hub assembly.
7. Remove the front brake caliper and brake scraper with a 15mm socket. Note: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent damage to the brake line.
8. Remove and discard the upper ball joint pinch bolt with a 15mm socket and 15mm wrench. Then remove the lower ball joint nut with a 18mm socket.
9. Remove the tie rod nut and separate with a 18mm socket.
10. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper control arm.
11. Separate the bearing carrier from the lower control arm.
12. Remove the drive shaft from the front bearing carrier.
13. With a short, sharp jerk, remove the drive shaft from the front gearcase.
14. Clean the anti-seize off the axle splines using a clean shop rag.
15. Inspect the threads and splines on the axle for nicks or burrs and replace if needed. A new front drive shaft is part number 1337043.
16. Inspect the CV boots to ensure there are no cuts, wear or damage and replace if needed.
17. If reusing the axle, remove and discard the circlip with a flat-head screwdriver.
18. Install a new compression ring into the groove on the end of the axle and ensure it is fully seated.
19. Apply new anti-seize to the inboard splines on the axle.
20. Inspect the anti-seize on gearcase and hub assembly for dirt or debris. Clean and apply new anti-seize, if necessary.
21. To reinstall the axle, put anti-seize lubricant on the gearcase end splines of the driveshaft.
22. Align the splines of the drive shaft with the front gearcase and reinstall the driveshaft. Use a rubber mallet to tap on the outboard end of the driveshaft, if necessary.
23. Perform a push/pull test on the axle to make sure the retaining ring is locked into the gearcase. Note: A push/pull test on the driveshaft is critical to make sure the snap ring is fully engaged.
24. Put the driveshaft into the front bearing carrier.
25. Put the upper and lower ball joint ends into the front of the bearing carrier. Now, torque the upper ball joint nut to 52 ft-lbs (70 Nm) and lower ball joint nut to 30 ft-lbs (40 Nm) + 90 degrees.
26. Install the tie rod, and torque nut to 30 ft-lbs (40 Nm) + 90 degrees.
27. Install the front wheel hub assembly, cone washer and wheel hub nut. Tip: Install the wheel hub cone washer with the domed side out.
28. Install the rotor onto the wheel hub assembly.
29. Install the caliper onto the knuckle with NEW mounting fasteners. Torque to 37 ft-lbs (50 Nm).
30. With the aid of an assistant, press the brakes and firmly hold the steering wheel while torquing the wheel hub nut to 177 ft-lbs (240 Nm).
31. Install a NEW cotter pin and bend the ends of the cotter pin in opposite directions. If necessary, slightly tighten the nut to align the cotter pin holes.
32. Install the wheel and lug nuts and tighten until fully seated.
33. Rotate the wheel and check for smooth operation.
34. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
35. Torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
36. Lower the vehicle completely to the ground.
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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