6-2
Drive System
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
NOTE: Specifications regarding the gear cases
(capacities, lubricant type, etc.) can be found in
Section 1 of this manual.
GENERAL INFORMATION
All gear cases are tagged beneath a cover bolt. This tag
is marked with a production date code, sequence code,
and a ratio code.
A. A “6” or “3.6” on the lower-right corner indi-
cates a 3.6:1 gear set ratio (10:36 teeth).
B. A “1” or “3.1” on the lower-right corner indi-
cates a 3.1:1 gear set ratio (11:34 teeth).
C. A “4.0” on the lower-right corner indicates a
4.0:1 gear set ratio (9:36 teeth).
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assem-
bling with these screws, start the screws carefully into
the housing; then use the following torque values.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Front Drive
Actuator/Electronic
Differential Lock
NOTE: The actuator is not a serviceable compo-
nent. If it is defective, it must be replaced.
NOTE: The actuator will operate only when the
ignition switch is in the ON position.
The front drive actuator is located on the side of the
front drive input housing. With the engine stopped and
the ignition switch in the ON position, a momentary
“whirring” sound can be heard each time the front
drive selector switch is shifted (400) or the electronic
differential lock is activated (H1/H2). If no sound is
heard, see Section 5. If the actuator runs constantly or
makes squealing or grinding sounds, the actuator must
be replaced.
REMOVING
1. Disconnect the connector on the actuator harness.
2. Using a T-30 torx wrench, remove the mounting
cap screw from the driveshaft side of the actuator.
AG926
3. Remove the mounting cap screw from below the
actuator on the suspension side.
Ring Gear Backlash
0.28-0.38 mm (0.011-0.015 in.)
Ring Gear End Play
0.1-0.2 mm (0.004-0.008 in.)
Size
New
Housing
Reassembled
Housing
M6 (Torx T-30 Recess)
8-9.5 ft-lb
6.5-9 ft-lb
M8 (Torx T-40 Recess)
25-31 ft-lb
21-25 ft-lb
M10 (Torx T-50 Recess)
37-45.5 ft-lb
31-38 ft-lb
Description
p/n
CV Boot Clamp Tool
0444-120
CV Boot Clamp Tool
0444-250
Internal Hex Socket
0444-104
Pinion Gear/Shaft Removal Tool
0444-127
Slide Hammer Kit
0444-225
Seal Installation Tool
0444-224
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