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2024 Polaris XPEDITION XP and ADV Front Upper A-Arm Removal and Installation

Required Tools and Supplies
8mm Allen SocketRatchet
8mm SocketTorque Wrench
15mm SocketBreaker Bar
18mm SocketDrill
19mm Socket3/16-Inch Drill Bit
15mm WrenchSoft Face Hammer
18mm WrenchFlat Head Screwdriver
PliersSafety Glasses
Rivet ToolShock Nut (part number 7548030)
RivetsBrake Line Rivet (part number 7621432)
Ball Joint Pinch Bolt (part number 7521333-65)Upper Control Arm Nuts (2) – (part number 7548030)
Ball Joint Pinch Nuts (part number 7548029)Shock Fastener (part number 7521334-65)
Nitrile GlovesShop Rags
Upper Control Arm Fasteners (2) – Rear (part number 7521334-105) Front – (part number 7521334-70)

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris XPEDITION.

To remove and install the front upper control arm on your Polaris XPEDITION XP or ADV, follow these steps:

1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key. 

2. Remove the wheel from the vehicle. 

  • Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground, but do not remove them at this time.
  • Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
  • Once safely elevated, remove the lug nuts and set aside. 
  • Remove the wheel and set aside. 

3. Remove the two brake shield fasteners with a 8mm socket and lift the shield off the brake disc.

4. With light pressure and high rotation speed, drill the brake line rivets out of the upper control arm to free the arm from the brake line. Use care to avoid damaging the brake line during this process.

5. Disconnect the brake line from its retention point near the lower shock mount.

6. Remove the lower shock mount fastener, nut and washer with a 18mm socket and 18mm wrench. Discard the fastener and nut.

7. Remove the upper ball joint pinch fastener with a 15mm socket and 15mm wrench and discard the nut.

8. Lift on the control arm while tapping on the bearing carrier with a soft face hammer. This will help loosen the ball joint end from the carrier and allow it to be removed.

9. Remove and discard the upper control arm nuts with a 18mm socket and 18mm wrench.

10. If a winch is installed, remove the four front winch fasteners with a 8mm Allen socket. The winch will now rest on the guide bolts.

11. Pivot the winch off the guide bolts to gain access to the front control arm fastener. Use care to avoid damaging the wiring harness. A retention point on the harness can be released to provide extra maneuverability.

12. Pivot the winch forward as needed to remove the upper control arm fastener and washer.

13. Reinstall the winch on the guide bolts and allow it to rest until reinstallation.

14. Remove the remaining control arm fastener.

15. Pull the shock out and pivot the control arm around the brake line to remove from the vehicle.

16. If reusing the control arm, thoroughly clean with a shop rag before reinstalling.

17. Inspect the control arm bushings and pivot tube for wear or damage and replace as needed. Note: When reinstalling the bushings, ensure the tapered side is inserted into the arm. Also ensure the control arm bushings are fully installed inside the arm before installing the pivot seals.

18. If reusing the arm, inspect the ball joint and ball joint boot for wear, tears or damage and replace if necessary. 

19. Align the upper control arm with the mounting holes in the frame, ensuring the brake line rests on top of the arm and on the rear side of the shock.

20. Reinstall the rear control arm fastener and washer from the front of the vehicle and secure with a new nut.

21. If a winch is installed, lift it off the guide bolts and pivot out to gain access to the front control arm mounting hole.

22. Reinstall the control arm fasteners and washers from the front of the vehicle.

23. Reinstall the winch on the guide bolts and align the mounting holes.

24. Reinstall the four front winch fasteners, and torque to 63 ft-lbs (85 Nm).

25. Install a new nut onto the front control arm fastener.

26. Insert the ball joint end into the bearing carrier and install a new fastener from the front of the vehicle.

27. Secure the carrier fastener with a new nut.

28. Align the shock mounting holes and install a new fastener from the rear of the vehicle. Secure with a new nut.

29. Torque the control arm fasteners to 88 ft-lbs (120 Nm).

30. Torque the ball joint pinch fastener to 44 ft-lbs (60 Nm).

31. Torque the shock mount fastener to 88 ft-lbs (120 Nm).

32. Press the brake line into its retention point near the lower shock mount.

33. Align the brake line retainers with their mounting holes and secure with new rivets.

34. Align the brake shield with the mounting holes on the brake caliper.

35. Reinstall the shield fasteners, and torque to 9 ft-lbs (10 Nm).

36. Install the wheel on the vehicle and tighten the lug nuts until fully seated.

37. Once installed, safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing. 

38. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern. 

39. Finally, lower the vehicle completely.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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© 2023 Polaris Industries Inc.

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