7.9
FINAL DRIVE
7
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.
Inner Plunging Joint / Boot Replacement
1. Remove th e fr ont dr ive shaft from the vehicle (see
“FRONT DRIVE SHAFT - Removal”).
2. Remove and discard the boot clamps.
3. Remove the large end of the boot from the plunging
join
t and slide the boot back.
4. Use a soft-faced hammer or brass drift to separate the
p
lunging joint from the drive shaft.
NOTE: If u sing a bras s dr ift, be sur e to ta p on t he
inne
r race of the joint only.
5. Make sure the circlip remains on the shaft and not left
in the joint. Disc
ard the circlip.
6. Remove the boot from the drive shaft.
IMPORTANT: If the grease in
the joint is obviously
contaminated with water and/or dirt, the joint should
be replaced.
7. Thoroughly clean the joint with an appropriate solvent
a
nd dry the joint to prevent any residual solvent from
being left in the joint upon reassembly.
8. Visually inspect the joint by tiltin
g the inner race to one
side to expose each ball. Severe pitting, galling, play
between the ball and its cage window, any cracking
or damage to the cag e, pitting or galling or chips in
raceways call for joint replacement.
9. Clean the splines on the end of the shaft and apply a
lig
ht coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first)
o
nto the drive shaft and position the boot in it’s groove
machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
12. Grease the joint with the special joint grease provided
i
n the boot replacement kit. Fill the cavity behind the
balls and the s plined hole in the joint’s inner race.
Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
NOTE: The amount of grease that’s provided is pre-
me
asured, so use all the grease.
13. Fully compress the joint and push the drive shaft firmly
into t
he inner race.
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the drive
shaft unti
l it locks into place.
16. Pull on the joint to make sure it is sec
urely locked into
place.
17. Remove excess grease from the plun ging joint’s
e
xternal surfaces and place the excess grease in the
boot.
18. Pull the boot over the joint and position the boot lips
i
nto the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
19. Install and secure the small clamp on the boot using
th
e “earless” clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
Complete disassembly of the plunging joint is
NOT recommended. The internal components
are a precision fit and develop their own
characteristic wear patterns. Intermixing the
internal components could result in looseness,
binding, and/or premature failure of the joint.
The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes
or mix with other lubricants.
Boot Replacement Grease Requirement:
Grease Service Kit
1350047 (50g)
Inner Plunging Joint Capacity: 80g
CV Boot Clamp Pliers
Earless Type: 8700226
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