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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
09/05/2023

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

Required Tools and Supplies
5mm Allen SocketRatchet
15mm SocketTorque Wrench
19mm SocketBreaker Bar
21mm SocketFlat Head Screwdriver
30mm SocketAnti-Seize
15mm WrenchUpper Bearing Carrier Fastener
21mm WrenchUpper Bearing Carrier Nut
Wire Hanger, Rope or Retention StrapCompression Ring
Rear Brake Caliper Mounting FastenersSafety Glasses
Shop RagsNitrile Gloves

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 rear 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. 

3. Loosen the hub nut with a 30mm socket.

4. 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.

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

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

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

11. Remove the brake disc and set aside.

12. Remove the hub nut from the drive shaft.

13. Remove the upper bearing carrier fastener, nut and washer with a 21mm socket and 21mm wrench.

14. Pivot the bearing carrier down and separate the drive shaft from the carrier.

15. Support the upper control arm with a wire hanger, rope or retention strap to ease axle removal.

16. With a short, sharp jerk, remove the drive shaft from the rear gearcase.

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

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

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

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

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

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

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

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

25. Ensure any items used to secure the upper control arm are removed from the wheel well.

26. Rotate the bearing carrier up into the axle and align the mounting holes.

27. Install a new upper bearing carrier fastener from the rear of the vehicle and secure with the retained washer and new nut.

28. Torque the upper carrier fastener to 148 ft-lbs (200 Nm).

29. Reinstall the hub nut onto the drive shaft.

30. Press the brake disc onto the wheel hub until fully seated.

31. 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.

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

33. Torque the fasteners to 37 ft-lbs (50 Nm).

34. Tighten the set screw on the back side of the caliper and turn the screw until the pads touch the brake disc. 

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

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

37. 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. Torque the hub nut to 88 ft-lbs (120 Nm).

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

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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