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9926595 R01 - 2015-2016 RANGER EV Service Manual
© Copyright Polaris Industries Inc.
5.27
6. If a tight spot is felt during rotation, loosen the
backlash screw another 1/8 turn (counterclockwise).
Perform the previous step again. Repeat this
procedure until the pinion shaft rotates smoothly 4
times (1 revolution of ring gear).
Fine-Tuning Backlash Adjustment For Noise
Reduction
Perform this fine-tuning adjustment of backlash
setting only if noise is evident after the gearcase is
installed and tested. Note there are two procedures
based on the type of noise detected.
• Adjustments should be made in very small movements
of the backlash adjustment screw (about 1/32 turn at a
time).
• 1/32 turn removes or adds approximately .001 in.
(.025mm) of backlash at the ring gear.
• Test the vehicle after each adjustment.
• Damage or added noise can result from improper
adjustment. Be sure to follow the guidelines in the
adjustment procedures.
• Identify the type of noise as described below and
perform the appropriate fine-tuning adjustment that
follows.
Rattle or clicking noise at higher speeds when in two-
wheel drive (2WD)
7. Turn the backlash adjustment screw in (clockwise) 1/
32 of a turn.
8. Test drive vehicle to re-evaluate noise performance.
9. If noise is still present, turn the screw in an additional
1/32 turn and re-test. DO NOT continue to make
adjustments. Anything more than this may result in
slight binding of the gear onto the front shim and may
cause excessive wear on the thrust button and shim.
Gear mesh noise in 2WD or 4WD:
10. Turn the backlash adjustment screw out (counter-
clockwise) 1/32 of a turn.
11. Test drive vehicle to re-evaluate noise performance.
12. If noise is still present, turn the screw out an
additional 1/32 turn and re-test. Repeat the
procedure if necessary up to a maximum of 1/8 turn
out from the base setting (4 increments of 1/32 turn
each time). DO NOT continue to make adjustments
past 1/8 turn or the rattle / clicking noise previously
mentioned could result.
GEARCASE INSTALLATION
1. To install gearcase, reverse removal procedure.
2. Torque mounting bolts to specification.
TORQUE
Front Gearcase Mounting Bolts:
30 ft-lb (41 Nm)
3.
4. Add the proper lubricant to the front gearcase. Check
drain plug for proper torque. Refer to Chapter 2 for
fluid fill and change information.
Demand Drive
(PN 2877922)
Front Housing Capacity:
6.1 oz. (180 ml)
FINAL DRIVE
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