Required Tools and Supplies | |
| 8mm Socket | 15mm Socket |
| 18mm Socket | 19mm Socket |
| 15mm Wrench | 18mm Wrench |
| T25 TORX® | Ratchet |
| Torque Wrench | Breaker Bar |
| Soft Face Hammer | Wire Hanger, Rope or Retention Strap |
| Upper Control Arm Nuts | Lower Shock Mount Nut |
| Upper Ball Joint Nut | 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 upper 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. On NorthStar models, remove the front bumper and disconnect the auxiliary lights. Then remove the winch. Refer to your service manual for bumper and winch removal.
8. Remove the lower shock fastener from the upper control arm with a 18mm socket and 18mm wrench.
9. Remove the screws that fasten the brake line retainers to the upper control arm with a T25 TORX®, and then remove the brake line from the clip.
10. Remove the two brake scraper bolts with a 8mm socket and set aside.
11. Remove the upper ball joint pinch bolt and nut from the knuckle with a 15mm socket and 15mm wrench.
12. Using a soft face hammer, tap on the knuckle to loosen the upper control arm ball joint end while lifting upward on the control arm. Completely remove the ball joint end from the knuckle.
13. Remove the four steering gearbox fasteners from the chassis with a 15mm socket.
14. Loosen and remove the upper control arm fasteners with a 18mm wrench and 18mm socket, and remove from the vehicle.
15. Examine the control arm bushings and pivot tube. Replace if worn. Discard the hardware. Note: The locking agent on the existing bolts were destroyed during removal. Do NOT reuse the old hardware. Serious injury or death could result if fasteners come loose during operation.
16. If reusing the control arm, thoroughly clean with a shop rag before reinstalling.
17. If replacing, insert NEW pivot tubes, 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.
18. Install the upper control arm assembly onto the vehicle frame with NEW fasteners, and torque to 89 ft-lbs (120 Nm).
19. Install the steering gearbox fasteners to the chassis, and torque to 37 ft-lbs (50 Nm).
20. Insert the upper control arm ball joint end into the knuckle and install a NEW upper ball joint pinch bolt and nut into the knuckle, and torque to 52 ft-lbs (70 Nm).
21. Install the screws that fasten the brake line retainers to the upper control arm, and then put the brake line in the clip. Torque to 71 in-lbs (8 Nm).
22. Install the brake scraper and two fasteners. Torque to 88 in-lbs (10 Nm)
23. Attach the shock to the control arm with NEW fasteners, and torque to 59 ft-lbs (80 Nm). Note: Reference service manual for fastener orientation and torque location.
24. On NorthStar models, reinstall the winch, front bumper and connect auxiliary lights. Torque to specification. Refer to your service manual for winch and bumper installation.
25. Install the wheel on the vehicle and tighten the lug nuts until fully seated.
26. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
27. Torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
28. 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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