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

2024 Polaris XPEDITION XP and ADV Front Drive Shaft Removal and Installation

Required Tools and Supplies
5mm Allen SocketRatchet
6mm Allen SocketTorque Wrench
15mm SocketBreaker Bar
18mm SocketPliers
19mm SocketFlat Head Screwdriver
30mm SocketSoft Face Hammer
15mm WrenchAnti-Seize
18mm WrenchCotter Pin
Upper Ball Joint Pinch FastenerCompression Ring
Lower Ball Joint NutSafety Glasses
Front Brake Caliper Mounting FastenersNitrile Gloves
Wire Hanger, Rope or Retention StrapShop Rags

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 drive shaft 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 center cap from the wheel with a flat head screwdriver.

3. Remove and discard the cotter pin on the axle shaft with pliers.

4. Loosen the axle nut with a 30mm socket.

5. Loosen the lug nuts while the vehicle is on the ground with a 19mm socket with a breaker bar, but do not remove them at this time.

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

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

8. Remove the wheel and set aside. 

9. Loosen the brake pad adjuster screw on the brake caliper with a 5mm Allen socket.

10. Remove and discard the upper and lower caliper mounting fasteners with a 15mm socket.

11. Remove the caliper from the front hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.

12. Remove the castle nut, cone washer and the brake disc.

13. Remove the wheel hub and set aside.

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

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

16. Remove and discard the lower ball joint nut with an 18 mm socket.

17. Lightly tap on the bearing carrier with a soft face hammer while lifting on the upper control arm to separate the upper ball joint from the carrier.

18. Before continuing, support the bearing carrier with a wire hanger, rope or retention strap to avoid damaging the steering rod.

19. Support the upper control arm with a wire hanger, rope or retention strap to create more room for removal of the axle.

20. Remove the lower ball joint end from the bearing carrier. Tip: If the ball joint doesn’t move, tap the carrier with a soft face hammer to free the ball joint end.

21. Remove the drive shaft from the bearing carrier. If necessary, reposition the bearing carrier to create more space for removal of the drive shaft.

22. With a short, sharp jerk, remove the drive shaft from the front gearcase.

23. Clean the anti-seize off the drive shaft splines using a clean, dry cloth.

24. Inspect the threads and splines on the drive shaft for nicks or burrs and replace if needed. 

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

26. Remove and discard the compression ring on the drive shaft with a flat head screwdriver.

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

28. Apply new anti-seize to the inboard splines on the drive shaft.

29. Align the splines on the drive shaft with the gearcase and push in firmly on the shaft until the compression ring is fully engaged in the gearcase. 

30. Lightly pull on the shaft to ensure the compression ring is fully engaged.

31. Insert the shaft into the bearing carrier and push the carrier in to seat the shaft.

32. Install a new nut on the lower ball joint end. Counter-hold the ball joint end to tighten the nut with a 6mm Allen socket and 18mm wrench.

33. Ensure any items used to secure the bearing carrier are removed from the wheel well.

34. Reinstall the upper ball joint pinch fastener from the front of the vehicle and secure with a new nut. Before continuing, ensure any items used to secure the upper control arm and wheel carrier are removed from the wheel well.

35. Insert the upper ball joint end into the bearing carrier and secure with a new nut.

36. Align the shock with the lower mount and secure with the retained washer and a new fastener.

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

38. Torque the lower ball joint nut to 29 ft-lbs (40 Nm) + 90 degrees.

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

40. Install the wheel hub onto the drive shaft and push in until fully seated.

41. Reinstall the washer with the domed side out, and secure with the retained castle nut.

42. Reinstall the brake disc on the wheel studs.

43. 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.

44. Align the caliper with the mounting holes on the hub and install two new caliper fasteners.

45. Torque the fasteners to 44 ft-lbs (60 Nm).

46. Tighten the set screw on the back side of the caliper until the pads touch the brake disc. 

47. Loosen the set screw a half turn to allow the brake disc to move. 

48. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.

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

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

51. Torque the castle nut to 177 ft-lbs (240 Nm).

52. Insert a new cotter pin, and bend around the castle nut to secure. If necessary, tighten the castle nut to align the cotter pin holes.

53. Push the dust cap onto the wheel and ensure it is fully seated.

54. 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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