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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
9/5/2023

2024 Polaris XPEDITION XP and ADV Front Gearcase Fluid Replacement

Required Tools and Supplies

  • 8mm Allen Socket
  • Ratchet
  • Torque Wrench
  • Demand Drive Fluid
  • Drain Pan
  • Fluid Filler
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris XPEDITION. For optimal performance, always use Polaris-recommended fluids as described in your Owner’s Manual.

To change the front gearcase fluid on your Polaris XPEDITION XP or ADV, follow these steps:

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

2. Place a drain pan underneath the front gearcase drain plug. Tip: Placing a rag in the bottom of the drain pan will help prevent the splashing of fluid.

3. Clean the area around the fill plug in the passenger side front wheel well. 

4. Remove the front gearcase fill plug with an 8mm Allen socket, and set aside.

5. Move underneath the vehicle and locate the drain plug through the hole in the skid plate.

6. Clean the area around the drain plug.

7. Remove the drain plug with an 8mm Allen socket, and allow the fluid to drain completely.

8. Clean any dirt or debris from the fill and drain plugs.

9. Inspect the O-rings on both plugs, and replace if necessary.

10. Reinstall the drain plug, and torque to 8-10 ft-lbs (11-14 Nm).

11. Fill the gearcase through the fill plug hole until fluid reaches the bottom threads and begins to spill out. The fluid capacity is 10-11.83 fl. oz (300-350 mL). Demand Drive Fluid is part number 2877922 for one quart.

12. Reinstall the gearcase fill plug, and torque to 8-10 ft-lbs (11-14 Nm).

13. Once filled, clean any residual fluid off the vehicle and inspect for leaks.

14. Dispose of the used fluid properly at your local recycling center.

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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