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POLARIS OFF-ROAD VEHICLES
CENTRO DE AYUDA
10/4/2023

2024 RZR XP Front Drive Shaft Removal and Installation

Required Tools and Supplies
15mm SocketTorque Wrench
19mm SocketBreaker Bar
30mm SocketPliers
15mm WrenchSoft Face Hammer
RatchetPick Tool
Castle NutAnti-Seize
Upper Ball Joint NutBrake Caliper Fasteners
Tie Rod NutCotter Pin
Safety GlassesNitrile Gloves
Shop TowelsWire 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 front 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 while the vehicle is on the ground with a 19mm socket with breaker bar, but do not remove them at this time.

3. Remove and discard the cotter pin with pliers.

4. Loosen the wheel hub castle nut with a 30mm socket.

5. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.

6. Once safely elevated, remove the lug nuts and set aside. 

7. Remove the wheel and set aside. 

8. Remove and discard the caliper mounting fasteners and remove the brake caliper from the brake disc.

9. Carefully remove the caliper from the hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.

10. Remove and discard the castle nut and cone washer.

11. Pull the wheel hub off the assembly and set aside.

12. Remove and discard the upper and lower ball joint pinch bolts and nuts with a 15mm socket and 15mm wrench.

13. Lightly tap on the bearing carrier with a soft face hammer to separate the upper ball joint end from the bearing carrier.

14. Pivot the assembly down to separate the drive shaft from the bearing carrier.

15. With a short, quick pull, remove the drive shaft from the gearcase.

16. Clean the anti-seize off the axle splines using a clean shop rag.

17. Inspect the threads and splines on the axle for nicks or burrs and replace if needed. 

18. Inspect the CV boots to ensure there are no cuts, wear or damage, and replace if needed.

19. Inspect the drive shaft O-ring for wear, cracks or other damage, and replace if necessary.

20. Remove and discard the compression ring on the drive shaft with a pick tool.

21. Install a new compression ring into the groove on the end of the drive shaft and ensure it is fully seated. 

22. Put anti-seize on the gearcase end splines of the drive shaft.

23. Install the drive shaft in the transmission. If necessary, use a rubber mallet to tap the outboard end of the drive shaft.

24. Install the wheel hub assembly to the bearing carrier.

25. Install the upper ball joint end into the bearing carrier.

26. Install new upper and lower ball joint pinch bolts and nuts. Torque to 40 ft-lbs (55 Nm).

27. 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.

28. Install new upper and lower caliper mounting fasteners. Torque to 29 ft-lbs (40 Nm).

29. Install a new cone washer and castle nut. Torque to 177 ft-lbs (240 Nm). Ensure to install the cone washer with the domed side out.

30. Install a new cotter pin in the drive shaft. Note: If necessary, slightly tighten the wheel hub castle nut to align the nut and the drive shaft holes.

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

32. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing. 

33. Once lowered, torque the lug nuts to 121 ft-lbs (165 Nm) in a crisscross pattern. 

34. 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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