7.22
FINAL DRIVE
P
RELIMINARY
V
ERS
I
ON
4. Set the gearcase upright.
5. Back the adjustment screw out while rotating the pinion
shaft. The pinion shaft should rotate freely during four
complete rotations. The four pinion shaft rotations ensures
that the ring gear completes one full rotation.
6. If a tight spot is felt during rotation, loosen the backlash
adjustment screw further and repeat pinion shaft rotation.
Repeat this procedure until the pinion shaft rotates
smoothly four complete times (1 revolution of ring gear).
Gearcase Installation
1. Install the gearcase back into the vehicle through the LH
wheel well area, between the upper and lower A-arms.
2. Install the propshaft assembly onto the front gearcase input
shaft. Use a NEW spring pin in the front propshaft.
3. Install the (4) bolts that secure the front gearcase to the
frame and torque to 30 ft. lbs. (41 Nm).
4. Install the vent line.
5. Connect the AWD wire harness.
6. Refer to “FRONT DRIVE SHAFT - Drive Shaft
Installation” and install both front drive shafts into the front
gearcase.
7. Add the proper lubricant to the front gearcase. Refer to
Chapter 2 for fluid fill and change information.
= T
Front Gearcase Mounting Bolts:
30 ft. lbs. (41 Nm)
Polaris Demand Drive Plus
(PN 2877922)
Front Housing Capacity
6.75 fl. oz. (200 ml)
30 ft. lbs.
Install
Vent Line
Connect
Harness
(41 Nm)
AWD Harness
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