Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
7.17
2. Remove bolts and output shaft cover.
AWD FRONT HOUSING
DISASSEMBLY, CONT.
3. Remove output shaft assembly, large shim, and
thrust button with its small shim.
4. Clean all parts and inspect spacers for wear.
Inspect ring gear for chipped, broken, or missing
teeth.
5. Remove pinion cover and O-ring.
6. Unscrew fill plug and remove pinion shaft
assembly. Inspect pinion gear for chipped broken
or missing teeth.
NOTE: Pinion shaft assembly will not clear the fill
plug unless it is backed out.
AWD FRONT HOUSING
ASSEMBLY
1. Replace all O-rings, seals, and worn
components.
Bushings
2. Press pinion shaft seal into pinion cover until flush
with sealing surface.
3. Inspect pinion and output shaft bushings.