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Polaris SPORTSMAN 400 2003 - AWD Front Housing Disassembly; AWD Front Housing Assembly; AWD Front Housing Installation

Polaris SPORTSMAN 400 2003
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FINAL DRIVE
7.17
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 chippedbroken
or missing teeth.
NOTE: Pinionshaft assemblywillnot clear the fill plug
unless it is backed out.
AWD FRONT HOUSING
ASSEMBL
Y
1. Replace all O-rings, seals, and worn
components.
Bushings
2. Press pinion shaft sealinto pinioncover untilflush
with sealing surface.
3. Inspect pinion and output shaft bushings.
4. Inspect bearings on output and pinion shafts. To
replace, press new bearing on to shaft.
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