123
Drive System/Brake
System
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when servicing the gear case.
NOTE: Special tools are available from the Arctic
Cat Service Department.
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 indicates
a 3.6:1 gear set ratio (10:36 teeth).
B. A “1” or “3.1” on the lower-right corner indicates
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 assembling
with these screws, start the screws carefully into the
housing; then use the following torque values.
Specifications regarding the gear cases (capacities, lubri-
cant type, etc.) can be found in the General Information
section of this manual.
Front Drive Actuator
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 igni-
tion switch is in the ON position.
The front drive actuator is located on the left 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. If no sound is heard, see Elec-
trical System. If the actuator runs constantly or makes
squealing or grinding sounds, the actuator must be
replaced.
REMOVING
1. Remove the front inner fender panels; then discon-
nect 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.
AG927
4. Loosen but do not remove the mounting cap screw at
the front of the actuator; then slide the actuator to the
rear enough to clear the slotted mounting tab and the
selector shaft.
AG928
Description
p/n
CV Boot Clamp Tool
0444-120
Pinion Gear/Shaft Removal Tool
0444-127
Gear Case Seal Installer Tool
0444-224
Slide Hammer Kit
0444-225
Internal Hex Socket
0444-104
Backlash Gauge Tool
0544-010
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
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.)
