|Required Tools and Supplies
|Flat Head Screwdriver
|Upper Bearing Carrier Nut
|Brake Caliper Fasteners
|Wire Hanger, Rope or Retention Strap
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RZR.
To remove and install the rear drive shaft on your RZR XP, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key.
2. 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.
3. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
4. Once safely elevated, remove the lug nuts and set aside.
5. Remove the wheel and set aside.
6. Remove and discard the cotter pin with pliers.
7. Remove and discard the castle nut and cone washer with a 30mm socket.
8. Remove and retain the brake line cover fasteners and remove the cover with a 10mm socket and 10mm wrench.
9. Remove and discard the brake caliper fasteners, and remove the brake caliper from the brake disc with a 15mm socket.
10. Carefully remove the caliper from the hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.
11. Remove the wheel hub assembly from the bearing carrier. Tip: A puller tool may be required to remove the bearing carrier.
12. Remove the bolts, washers and nuts for the upper and lower radius rods with a 15mm socket and 15mm wrench. Discard the nuts.
13. While supporting the trailing arm from underneath, remove the lower shock mounting bolt and nut with a 18mm socket and 18mm wrench. Discard the nut.
14. Remove the stabilizer bar mount bolt and nut with a 15mm socket and 15mm wrench. Discard the nut.
15. Lift the rear end of the trailing arm assembly so the rear drive shaft is parallel with the ground.
16. Support the drive shaft with one hand while removing the trailing arm assembly outward to remove the drive shaft from the bearing carrier.
17. Lower the trailing arm.
18. With a short, quick pull motion, remove the drive shaft from the transmission splines.
19. Clean the anti-seize off the axle splines using a clean shop rag.
20. Inspect the threads and splines on the axle for nicks or burrs and replace if needed.
21. Inspect the CV boots to ensure there are no cuts, wear or damage and replace if needed.
22. Inspect the drive shaft for wear, cracks or other damage and replace if necessary.
23. Remove and discard the circlip on the drive shaft.
24. Install a new circlip into the shaft so that it is fully seated.
25. Put anti-seize on the transmission end splines of the drive shaft and put the drive shaft in the transmission. If necessary, use a rubber mallet to tap the outboard end of the drive shaft.
26. Put Loctite® 7649 on the hub assembly splines, allowing 90 seconds for the primer to dry.
27. Put Loctite® 680 on the hub end splines of the drive shaft. Apply around the circumference of the end of the hub side splines and then move down in a spiral pattern.
28. While supporting the trailing arm from underneath, swing the rear trailing arm assembly outward and upward to a position where the rear drive shaft can be put into the bearing carrier.
29. Install the stabilizer bar mount bolt and a new nut. Torque to 40 ft-lbs (55 Nm).
30. Install the lower shock mounting bolt and a new nut. Torque to 129 ft-lbs (95 Nm).
31. Install the upper and lower radius rod bolts, washers and new nuts. Torque to 51 ft-lbs (70 Nm) + 90 Degrees.
32. Install the wheel hub assembly on the bearing carrier. Tip: Be sure to remove any straps or supports used.
33. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads. Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.
34. Install new brake caliper fasteners, and torque to 51 ft-lbs (70 Nm).
35. Reinstall the brake line cover and retained fasteners. Torque to 88 in-lbs (10 Nm).
36. Install a new cone washer and castle nut, and torque to 177 ft-lbs (240 Nm). Ensure that the cone washer is installed with the domed side out.
37. Install a new cotter pin.
38. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
39. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
40. Once lowered, torque the lug nuts to 121 ft-lbs (165 Nm) in a crisscross pattern.
41. 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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