Required Tools and Supplies | |
| 15mm Socket | 18mm Socket |
| 19mm Socket | 30mm Socket |
| 15mm Wrench | 18mm Wrench |
| Ratchet | Torque Wrench |
| Breaker Bar | Soft Face Hammer |
| Needle Nose Pliers | Wire Hanger, Rope or Retention Strap |
| Lower Control Arm Nuts | 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 lower control arm 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 and retain the lug nuts and set aside.
6. Remove the wheel and set aside.
7. Remove the cotter pin with a needle nose pliers. 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.
8. Remove the brake caliper and brake scraper with a 15mm socket. Note: Do not hang the caliper by the brake line. Use wire to hanger caliper to prevent damage to the brake line.
9. Remove the front wheel hub assembly.
10. Remove and discard the upper ball joint pinch bolt with a 15mm socket and 15mm wrench. Remove the lower ball joint nut with a 18mm socket.
11. Remove the tie rod nut and separate with a 18mm socket.
12. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper control arm.
13. Separate the bearing carrier from the lower control arm.
14. Remove the front bumper lower fastener and set aside with a 15mm socket and 15mm wrench.
15. Loosen and remove the lower control arm through bolt fasteners with a 18mm socket and 18mm wrench.
16. Remove the stabilizer bar link to the control arm fastener with a 18mm socket and 18mm wrench, and remove the control arm from the vehicle.
17. Examine the control arm bushings and pivot tube. Replace if worn and discard the hardware.
18. If reusing the control arm, thoroughly clean with a shop rag before reinstalling.
19. Inspect the ball joint and ball joint boot for wear, tears or damage and replace, if necessary.
20. If replacing, insert NEW pivot tube, control arm bushings and pivot seals into the control arm. Note: Make sure the control arm bushings are fully installed inside the control arm before installing the pivot seals.
21. Install the lower control arm assembly onto the vehicle frame with NEW fasteners, and torque to 89 ft-lbs (120 Nm).
22. Install the stabilizer bar link onto the control arm with a NEW fastener, and torque to 89 ft-lbs (120 Nm).
23. Install the front bumper lower fastener, and torque to 33 ft-lbs (45 Nm).
24. Put the drive shaft 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. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
34. Torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
35. 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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