Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 181 / 289

GENERAL INFORMATION
7.13
AWD STRUT CASTING
FRONT DRIVE AXLE SEAL
REPLACEMENT
1. Disassemble front hub. Refer to Page 7.3.
2. Remove the cotter pin and castle nut from the A-
arm ball joint. Separate A-arm from ball joint.
3. Remove the spindle and axle assembly from the
strut casting bearing by pulling the strut outward
as shown. Drive out the old seal, taking care not
to damage the tapered roller bearing. Install the
new seal until it bottoms against the shoulder in
the strut casting.
Pull
strut off
drive
shaft
4. Apply grease to the seal inner lip, reinstall the
spindle and axle assembly.
5. Reinstall the A-arm to the ball joint. Torque to 25
ft. lbs. (35 Nm).
NOTE: If the cotter pin hole does not align at the
above torque, tighten slightly until the cotter pin hole
aligns and install the pin with open ends toward rear
of machine.
BEARING REPLACEMENT
NOTE FOR FRONT DRIVE
AXLE AND FRONT HUB
NOTE: The front axle bearings have a larger I.D.
(1.0625
″
) than the hub bearings (1.000
″
). Be sure to
install the bearings with the larger I.D. in the strut
housing, and the bearings with the smaller I.D. in the
hub.
SEAL SLEEVE
REPLACEMENT
Front Drive Axle Seal Sleeve
A
Seal Sleeve
1. If front axle sleeves become damaged and leak
fluid they are replaceable. Using a hammer and
drift punch, remove the seal sleeve by driving it off
evenly being careful not to nick or damage the
sleeve mounting area (A).
2. Coat the sleeve mounting area (A) with silicone
and using extreme care, press the new seal
sleeve onto area (A) until it bottoms. Allow 12
hours for silicone to cure.