Polaris GEM eLXD User Manual

3 - 4 DRIVETRAIN
GEM Service Manual November 2007
DIFFERENTIAL
DESCRIPTION
The differential consists of a pinion gear and two
side gears in a cast aluminum case. The drive
motor is attached to the pinion gear. The side gears
are each attached to halfshafts
OPERATION
Rotation of the motor spindle is transferred to the
pinion gear. The pinion gear contacts the side
gears, forcing them to rotate, transferring power to
the halfshafts.
Fig. 3 Differential Mounting Bolts
1 - Upper mounting bracket & bolts
2 - Mounting bolts
3 - Lower mounting bracket & bolts
4 - Differential
REMOVAL
1. Open the hood.
2. Remove the halfshafts. See Halfshafts in this
section.
3. Remove motor. See Motor in Electrical section.
4. Remove the top 4 bolts and upper mounting
bracket that connect the differential to the
suspension frame mounting plate.
5. Remove the bottom 4 bolts and lower mounting
bracket that connect the differential to the
suspension frame.
6. Remove the differential by sliding it out the right
(passenger) side.
INSTALLATION
1. Add oil to new differential. Use 30 SAE engine
oil 16-oz.
2. Make sure that the spring clips are on the
splined differential shafts.
3. Position differential between front suspension
frame and mounting plate.
4. Install mounting brackets and bolts, 4 through
the lower mounting bracket into the front
suspension frame and 4 through the upper
mounting bracket and plate. Torque differential
mounting bolts to 225 in-lb.
NOTE: Do not over tighten, as threads will strip.
1. Install motor. See Motor in Electrical section.
2. Install halfshafts. See Halfshaft in this section.
3. Install spring/shock absorber upper mounting
bolt. Tighten to 60 ft-lb.
4. Close the hood.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds
Foot -
Pounds
Differential to front suspension frame
5/16” –18 NO 225 ---
Halfshaft to steering knuckle assembly
M16 x 1.5 YES --- 65
Motor to differential
¼ -- 20 YES 65 ---
Shock absorber upper bolt
M12 x 1.75 NO --- 60
Wheel lug nuts
12mm NO --- 65

Polaris GEM eLXD Specifications

General

Brand	Polaris
Model	GEM eLXD
Category	Utility Vehicle
Language	English