2011-2012 RANGER 800 XP / HD / CREW / 6x6 Chapter 8
Contents
1. WI Pa 10 14 ft Ibs FOR REASSEMBLY 14 19Nm Z Le end e Apply White Lithium we lt DR SA Based Grease a da N Le I Apply Polaris Crankcase Sealant 8 12 ft Ibs 11 16 Nm 12 18 ft Ibs 16 24 Nm Apply Loctite to the bolt threads 8 28 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 Exploded View Continued Ref Qty Description Ref Qty Description 1 2 Fill Plug 49 1 Shift Drum 2 1 Drain Plug Magnetic 50 1 Gear Sector 16T 3 2 Screw Self Tapping Torx 51 1 Gear Sector 31T 4 Screw Torx 52 1 Detent Pawl 5 20 Screw Self Tapping Hex 53 1 Detent Star 6 6 Screw Self Tapping Hex 54 1 Lockout Disc 7 6 Screw 55 1 Input Shaft 31T CREW Input Shaft 35T XP HD 8 1 Screw 56 1 Gear Snorkel 13T 9 1 Lock Nut 57 1 Gear Output 91T 10 1 Washer 58 1 Reverse Shaft 26T 11 2 Washer Fender 59 1 Pinion Center Drive 13T 12 2 Washer Cup 60 1 Shoe Chain Tensioner 13 1 Washer Fender 61 1 Cam Chain Tensioner 14 2 Pin 62 1 Bellcrank Shift Drum 15 2 Dowel Pin 63 1 Shift Shaft 16 6 Dowel Pin 64 1 Shift Collar 17 2 Retaining Ring External 65 1 Rail Shift Shaft 18 1 Sn2. agement Dog Shift Planetary Fork Differential Solenoid When Differential Lock is selected on the switch power is removed from the electrical solenoid allowing the solenoid plunger to retract Spring tension moves the shift fork back into place and engages the engagement dog to the side gear that is part of the planetary differential assembly This locks the rear differential as a solid rear axle increasing traction When switch position is set to Lock power is removed from the solenoid and spring tension retracts the plunger to engage the clutch gear and lock the differential Engagement Dog Past Shift Differential Solenoid 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 Transmission 1 Place vehicle a level surface and block the front wheels Elevate the rear of the vehicle and safely support the vehicle under the rear frame area Serious injury may result if machine tips or falls CAUTION Be sure machine is secure before beginning this procedure Always wear eye protection Remove the wheel nuts and washers from both rear wheels Remove the rear wheels and set them off to the side If internal transmission repair is required drain the transmission lubricant Remove the seat and side storage container to access the PVT system Disc
3. 8 12 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 17 Using T27 Torx driver remove the screws that secure the output gear U 18 Remove the shift drum V from the gearcase by moving the drum up and to the right to clear the shift shaft 19 Remove the output gear U and gear cluster assembly from the gearcase by pulling both assemblies straight up 20 Place the gear cluster assembly on aclean surface for inspection Gear Cluster Disassembly 21 Remove the bearing from the reverse shaft using a bearing puller Slide the engagement dog off of the reverse shaft see Figure 8 1 Ze Ki Y Al Reverse Shaft e N g N an ae Bearing x Ss amp TON 33T Gear EX N Si 4 Retaining ex Ring 4 Engagement S Dog Input Shaft Bearing Ki Silent Chain Bearing Figure 8 1 8 13 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 22 Remove the retaining ring and washer from the reverse shaft see Figure 8 1 23 Remove the bearing from the input shaft using bearing puller see Figure 8 1 24 Remove the 33T gear and needle bearing from the reverse shaft see Figure 8 1 25 The reverse shaft should slide out of the silent chain to separate the assembly 26 Remove the rest of the ball bearings f
4. E T Stabilizer Bar Retaining Bolts Stabilizer Linkage Rubber Bushing Nuts 17 ft Ibs 24 Nm 15 Apply anti seize to the splines of each rear drive shaft and insert them into the transmission 8 23 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 16 Attach the rear upper A arms to the bearing carrier on 21 If both adjustment jam nuts were moved adjust the each side and torque the fasteners to specification shift cable see Shift Cable Adjustment 22 Install the exhaust silencer and 2 retaining springs 23 Install the inner PVT cover and torque the 8 screws Rear Upper A Arm to Bearing Carrier Bolts to specification see Chapter 6 30 ft Ibs 41 Nm 24 Install the drive clutch driven clutch and drive belt Torque the clutch retaining bolts to specification see Chapter 6 17 Place the rear brake line into the retainer located on each rear upper A arm NOTE Align clutches as outlined in Chapter 6 25 Install the outer PVT cover and 9 screws Torque the screws to specification see Chapter 6 26 Install the brake switch harness below the outer PVT cover 27 Install the rear wheels washers and wheel nuts Torque the wheel nuts to specification e T Wheel Nuts Steel Wheels 35 ft Ibs 47 Nm 18 Attach the rear shocks to the frame and torque the Aluminum Wheels 30 ft Ibs 41 Nm 90
5. in an even criss cross pattern to evenly secure the cover Torque the screws to specification E T Gearcase Cover Bolts 25 30 ft Ibs 34 41 Nm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 11 Install all new seals into the gearcases Use the Rear 13 Install the sector gear 16T onto the shift drum shaft Output Seal Driver PN 2871698 and Rear Driveshaft Install the shift shaft assembly and sector gear 11T Seal Guide PN 2871699 to install the seals into the into the bushing pocket on the left side Align the gearcase halves refer to the following illustration to timing marks on the gears as shown identify the seals needing replacement 14 Install the lockout disc onto the shift drum shaft Be sure to install the lockout disc with the raised edge facing outward 15 Install the detent star onto the shift drum shaft Be sure to install the detent star with the raised edge facing 12 Thoroughly clean the shift shaft housing Be sure the outward transmission is in Reverse prior to reassembly 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 16 Install the detent pawl onto the shift shaft and carefully 19 Install the bellcrank onto the shift shaft Note the key install the compression spring splined on the bellcrank and shift shaft Install the nut and torque to specificat
6. the shift lever Disconnect cable end from the lever 5 Remove the retaining ring outer washer and both bushings from the shift lever 6 Slide the shift lever off the mounting bracket and out from the frame Installation 1 Repeat the steps in reverse order to install the gear shift lever 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 SHIFT CABLE Inspection Shift cable adjustment is necessary when symptoms include Noise on deceleration Inability to engage a gear Excessive gear lash noise Gear selector is moving out of desired range Inspect shift cable clevis pins and pivot bushings and replace if worn or damaged Adjustment NOTE The shift cable should be adjusted at the rear adjustment point located near the transmission If adjustment is needed beyond that remove the dash panel to access the shift cable adjustment point located underneath the shift lever 1 Place gear selector in neutral Make sure the transmission bell crank is engaged in the neutral position detents 2 Locate the shift cable adjustment point at the engine to transmission mount bracket With two open end wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Inside Jam Nut P Outside Jam Nut Jam Nut After turning the outside jam nut 1 1 2 turns Hold the outside jam nut with a wrench and t
7. 0 Screw Self Tapping Hex 50 1 Detent Pawl 2 2 Seal Triple Lip 51 1 Compression Spring Detent 3 1 Cover LH 52 1 Cover Sector 4 2 Bearing Ball 53 1 Bellcrank Shift Drum 5 1 Silent Chain 54 1 Lock Nut 6 1 Case RH 55 1 Rotary Switch 6 Pin 7 1 Bearing Ball 56 1 Retaining Ring 8 1 Sprocket 19T 57 1 Gear Sector 16T 9 1 Oil Deflector 58 1 Drain Plug Magnetic 10 2 Screw Self Tapping Torx 59 1 Detent Star 11 1 Output Gear 91T 60 1 O Ring 12 1 Retaining Ring 61 1 Gear 13T Snorkel 13 6 Screw Self Tapping Hex 62 1 Bearing Ball 14 1 Bearing Cover Center Drive 63 1 Retaining Ring 15 2 Retaining Ring 64 1 Snorkel Tube 16 1 Shim 65 7 Screw Torx 17 1 Bearing Ball 66 1 Shim 18 1 Pinion 13T Center Drive 67 2 Retaining Ring 19 1 Retaining Ring 68 1 Seal Triple Lip 20 1 Thrust Washer 69 1 Seal Triple Lip 21 1 Gear 36T Spur XP HD Gear 41T Spur CREW 71 2 Dowel Pin 22 1 Bearing Needle 72 1 Fill Plug 23 1 Washer 73 2 Compression Spring 25 2 Engagement Dog 6 Face 74 2 Retaining Ring 26 2 Retaining Ring 75 2 Washer Cup 27 2 Thrust Washer 76 1 Retaining Ring 28 1 Sprocket 38T 6 Face 77 1 Shim 29 1 Reverse Shaft 26T 78 1 Engagement Dog 30 1 Gear 33T 6 Face 79 1 Torsion Spring 31 1 Shift Collar 80 1 Fork Pivot Shift Rear Diff 33 2 Bearing 81 1 Side Gear 36T 34 1 Seal Triple Lip 82 1 Carrier Assembly 35 3 Bearing 83 1 Side Gea
8. Ring 37 Lightly tap on the bearing from the opposite side to remove it from the snorkel tube 34 Remove the snap ring and shim from the snorkel shaft 38 To remove the remaining bearing on the snorkel shaft remove the retaining ring and press the bearing off Snorkel Shaft Sy ay y SECHS Se Retaining Ring id 4 85 Use an arbor press to remove the snorkel tube from the snorkel shaft 39 Remove all seals from the gearcase halves and clean the cases in preparation for assembly 8 15 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 Snorkel Output Gear Backlash Procedure 1 Reassemble the snorkel shaft assembly by reversing the disassembly procedure see Transmission Snorkel Shaft Removal Disassembly in previous section Snorkel Shaft L Snorkel Tube Bearing Retaining Retaining 2 Ring A ve EN Shim 4 H Retaining Ring Bearing Shim Seal 2 Apply a small amount of white lithium grease on the threads of the snorkel tube Grease Threads 8 16 3 4 Install snorkel shaft into gearcase Using Snorkel Tool PA 50231 tighten snorkel tube about 10 full rotations Do not completely tighten snorkel tube Inspect the output gear assembly and replace bearings if needed Inspect each gear for damage chips or abnormally worn teeth Install output g
9. TRANSMISSION 4 4 8 TRANSMISSION 4X4 E Se eeh LEE 8 4 TORQUE ee 8 4 SPECIAL Lee 8 4 LUBRICATION EE 8 4 SEENEN irda Recess cis laa eech 8 4 REMOVAL INSTALLATION ae Eege e teen ean 8 4 SHIFT CABLE cee Scheele RS ES da eel ed da hem da a ae de aa agen ai 8 5 INSPECTION 5 M e 8 5 TRANSMISSION SERVICE Len ne din dE ita Sits waaay yg ats 8 6 GENERAL OPERATIONS geld aient annee 8 6 TRANSMISSION REMOVAL seas a cate thea cas de Weta ea 8 7 TRANSMISSION DISASSEMBLY nee nee meme ments en Ad 8 11 SNORKEL OUTPUT GEAR BACKLASH PROCEDURE 8 16 TRANSMISSION ASSEMBLY nent ahaa eee causes 8 18 TRANSMISSION INSTALLATION ana he ee 8 23 TROUBLESHOOTING stad ea othe bea na aren ia read Se 8 25 TRANSMISSION EXPLODED VIEW 2011 8 26 TRANSMISSION EXPLODED VIEW 2012 8 28 8 3 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 SPECIFICATIONS Torque Specifications ITEM TORQUE VALUE 12 18 ft lbs Bell Crank Nut 16 24 Nm 25 30 ft lbs Case Bolts 34 41 Nm Differential Cover 23 27 ft lbs Assembly Bolts 31 37 Nm e 23 27 ft lbs Different
10. aft and propshaft splines while positioning the transmission to allow the shafts to slide together 4 Install the engine to transmission mount bracket 5 Install the 2 rubber engine mounts into the engine crankcase 6 Position the engine to transmission mount bracket and install the 2 through bolts and 2 lower engine mount nuts loosely 7 Install the lower and rear transmission through bolts IMPORTANT Be sure the brake line is clear of the lower through bolt upon installation mount fasteners to transmission 8 Torque all specification KT Transmission Mounting Fastener Torque Front 5 16 Bolts 20 ft Ibs 27 Nm Lower Rear 3 8 Bolts 37 ft Ibs 50 Nm 9 Install the parking brake caliper assembly and torque the mount bracket fasteners to specification E Parking Brake Caliper to Mount Bracket 18 ft Ibs 24 Nm Mount Bracket to Transmission 40 ft Ibs 54 Nm 10 Connect electrical harnesses to the rear diff solenoid gear selector switch and vehicle speed sensor 11 Remove the tie straps retaining each drive shaft and the one retaining the exhaust pipe to the airbox Reinstall the air filter and airbox lid 12 Properly route the transmission vent line Be sure vent line is not kinked or pinched 13 Install the rear cargo box shock 14 Install the stabilizer bar to the frame and to each stabilizer linkage Torque fasteners to specification
11. ap Ring 66 2 Shift Fork 19 2 Retaining Ring 67 1 Vent Tube 20 2 Retaining Ring 68 1 Fork Pivot Shift Rear Diff 21 1 Retaining Ring 69 1 Gear 41T CREW Gear 36T XP HD 22 1 Retaining Ring External 70 1 Sprocket 38T 6 Face 23 1 Retaining Ring Internal 71 1 Gear 33T 6 Face 24 2 Retaining Ring External 72 1 Engagement Dog 6 Face 25 1 Retaining Ring External 73 1 Sprocket 19T 26 1 Thrust Washer 74 1 Engagement Dog 27 1 Shim 75 1 Engagement Dog Low 6 28 1 Shim 76 1 Side Gear 36T Disconnect 29 1 Shim 77 1 Side Gear 36T 30 2 Thrust Washer 78 6 Planet Gear Assembly 31 1 Bearing Needle 79 1 Cover 32 1 Bearing Ball 80 1 Carrier Assembly 33 3 Bearing 81 1 Brake Disc Hub Assembly 34 2 Bearing Needle 82 1 Bearing Cover Center Drive 35 1 Bearing Ball 84 1 Oil Deflector 36 1 Bearing Ball 85 1 Chain 37 2 Bearing Ball 86 1 Silent Chain 38 2 Bearing Ball 87 1 Solenoid 39 1 Torsion Spring 88 1 Rotary Switch 2 Pin 40 1 Compression Spring 92 1 O Ring 41 2 Compression Spring 98 1 O Ring 42 2 Compression Spring 94 1 O Ring 43 1 Torsion Spring 95 1 Seal Triple Lip 44 1 Compression Spring 96 1 Seal Triple Lip 45 1 Snorkel Tube 97 2 Seal Triple Lip 46 1 Cover Sector 98 1 Seal Dual Lip 47 1 Cover LH 100 1 Speed Sensor 48 1 Case RH 8 29 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Pola
12. clips thrust washers and shafts for wear 8 25 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 TRANSMISSION EXPLODED VIEW 2011 RANGER XP HD 800 PN 1332898 RANGER CREW 800 PN 1332872 23 27 ft Ibs 25 30 ft Ibs 4 31 37 Nm 34 41Nm ns S 22 ey P S E Ka Q A 10 15 ft Ibs 14 20 2 262 gt 20 30 in lbs CA 2 3 4 a SEALANT 4 8 12 ft lbs a f Nm 9 RK b on QX y y D VI D X a 2 ft Ibs D 23 27 ft Ibs P o a SCH 5 el 31 37 F m 2429 CG 10 14 ft lbs i 4 e pe 14 19 Nm SS ai y S e 5 9 K A S Ke S R s d Le d 8 12 ft Ibs e 11 16 Nm 5456 La 3 lt 4 e A 8 12ft Ibs 11 16 Nal j FOR REASSEMBLY e Xs Apply White Lithium 5 2 Based Grease x S 8 12 ft Ibs Za 11 16 Nm ES Apply Polaris Crankcase Sealant 12 18 ft lbs 16 24 Nm em Apply Loctite to the bolt threads 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 Exploded View Continued Ref Qty Description Ref Qty Description 1 2
13. connect the vehicle harness from the vehicle speed sensor located on the right hand side of the transmission 8 8 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 19 Remove the 3 fasteners retaining the parking brake 22 Remove the engine to transmission mount bracket mount bracket and remove the parking brake caliper from the vehicle as an assembly h Mount Bracket 20 Remove the 2 through bolts and 2 lower engine mount nuts from the engine to transmission mount bracket 21 Remove the 2 rubber engine mounts from the engine 8 9 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 25 Retain each rear drive shaft to the lower A arm to keep 28 Tie the exhaust pipe to the airbox to hold it up during them out of the way during transmission removal transmission removal Remove airbox lid and air filter RK Cg Tie Strap A 26 Using a 15mm socket and ratchet remove the 29 Remove lower clip and pin from the cargo box shock retaining nut from the upper portion of the stabilizer Tie the shock out of the way or completely remove it bar linkage bushing on each side of the vehicle 30 With the help of an assistant lift up on the transmission and shift it over to the side to clear the vertical frame support 27 Using 1 2 socket and ratchet re
14. d drive chain following these precautions The case half rear output seal should be removed prior to differential installation as seal damage can occur with seal installed due to the angle of entry Install differential sliding geardog onto the shift fork arms at the same time the silent chain is installed The differential gear bearing may be lightly tapped into place The output seal can be installed once the assembly is in place 9 Tensioner Installation NOTE Case halve mating may be difficult due to tensioner pressure on the silent chain during installation Release tension at the ratcheting cam to aid case half installation Install the tensioner spring after the case halves are mated but not yet touching Assemble the tensioner cam and tensioner shoe and place them into the transmission Insert the front pin through the tensioner cam and the rear pin through the tensioner shoe Spring Leg Top View 8 20 e Place the spring over the front pin and hook the spring leg under the cam View From Left Side of Transmission Forward Lift Spring Over Rear Hook Spring Leg Under Cam Mounting Pin Lift the end of the spring and over the rear The tensioner cam will lift the shoe to provide chain tension 10 Apply a continuous bead of Crankcase 3 Bond Sealant PN 2871557 to the LH gearcase mating surface and install the cover Install and tighten the 20 screws
15. ear assembly Be sure to properly mesh the snorkel shaft bevel gear with output bevel gear Install the 4 torx screws A that secure the output gear assembly Torque the screws to specification 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 11 Once backlash is set apply Loctite 242 to threads S ST and install locking screw to secure the snorkel tube Output Gear Retaining Screws 8 12 ft Ibs 11 16 Nm Locking screw fits in the slots of the snorkel tube to retain it 7 Tighten the snorkel tube until it is lightly seated using the snorkel tool PA 50231 Turn the output shaft to prevent binding while tightening the snorkel tube Make sure the snorkel shaft gear and output bevel gear have zero lash NOTE It is important to have zero lash between the output gear and the snorkel shaft gear If there is binding or excess lash tighten or loosen the snorkel shaft until there is zero lash IMPORTANT Do not overtighten the snorkel tube Gears should rotate freely without binding 8 Look down into the gearcase at the snorkel locking screw hole opening to reference your starting point 9 Slowly rotate the snorkel tube counterclockwise while counting the number of notches passing through the hole opening as you rotate the tube Rotate the snorkel tube to the 7th notch from the seated position obtained in step 7 DC Count 7 n
16. ial Solenoid 31 37 Nm 10 14 ft lbs Drain Fill Plug 14 19 Nm 8 12 ft lbs Gear Sector Cover 11 16 Nm 20 30 in Ibs Oil Deflector Shield Screws 2 3 3 4 Output Gear Assembly 8 12 ft Ibs Retaining Screws 11 16 Nm Park Brake Disc 10 15 ft Ibs Mounting Bolt 14 20 Nm 8 12 ft lbs Snorkel Tube Locking Screw 11 16 Nm H 8 12 ft lbs Shift Fork Retaining Screws 11 16 Nm Transmission Mounting Bolts 20 ft lbs Front 5 16 Bolts 27 Nm Transmission Mounting Bolts 37 ft lbs Lower Rear 3 8 Bolts 50 Nm 8 12 ft Ibs Vehicle Speed Sensor Bolt 11 16 Nm Special Tools PART NUMBER TOOL DESCRIPTION PA 50231 Snorkel Tool 2871698 Part of 2871702 Kit Rear Output Seal Driver 2871699 Part of 2871702 Kit Rear Driveshaft Seal Guide 2871282 Bearing Seal Driver 50 mm SPX Corp 1 800 328 6657 or http polaris spx com 8 4 Lubrication Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity 33 8 oz 1000 ml SHIFT LEVER Removal 1 Remove the 2 push rivets retaining the dash panel and remove the panel from the dash to access the shift lever 2 Remove the shift knob cover retaining screw and shift knob from the shift lever Cable Washer Clip Bushings Retaining Ring Remove grommet around shift lever from the dash 4 Remove clip and washer retaining the shift cable to
17. ighten the inside jam nut clockwise until it is tight against the bracket Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable Use this procedure to loosen or tighten the shift linkage cable as needed 8 5 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 TRANSMISSION SERVICE General Operation The RANGER 4x4 transmission has two traction operational modes Differential Lock and Differential Unlock Locking the rear differential is beneficial in low traction and rough terrain conditions Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains Differential Lock Differential Unlock When Differential Unlock is selected on the switch the rear differential becomes unlocked for tighter turns An electrical solenoid mounted in the rear portion of the transmission actuates the shift fork The solenoid plunger extends out to move the shift fork and slides the engagement dog away from the side gear that is part of the planetary differential assembly This unlocks the rear differential The rear drive shafts are now dependent on the differential allowing for tighter turns When switch position is set to Unlock the solenoid is powered and the plunger extends disengage the clutch gear and N unlock the Le differential
18. ion Bellcrank Nut 12 18 ft Ibs 16 24 Nm 20 Install the transmission gear selector switch and secure the switch with the retaining ring 21 Install the brake disc assembly onto the output shaft Apply Loctite 262 or 2760 to the mounting bolt threads and torque the bolt to specification 17 Install a new O ring on each shift shaft Apply a small Brake Disc Hub amount of white lithium grease on the O rings shift shafts and component contact surfaces prior to installing the sector cover Park Brake Disc Mounting Bolt 10 15 ft Ibs 14 20 Nm 18 Apply Crankcase Sealant 3 Bond PN 2871557 onto the cover and transmission case mating surface Install the sector cover and torque the bolts to specification Sector Cover Bolts 8 12 ft Ibs 11 16 8 22 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 Transmission Installation 1 If transmission lubricant was drained fill the transmission with the specified amount of Polaris AGL Plus prior to installation S Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity 33 8 1000 ml 2 Apply Polaris Premium All Season Grease PN 2871423 to splines of front output shaft 3 With the help of assistant position the transmission into the frame from the rear of the vehicle Align the output sh
19. move the two fasteners that secure the stabilizer bar to the main frame on each side Remove the stabilizer bar from NOTE The propshaft will slide off during removal the vehicle 31 With the help of an assistant lift up on transmission and carefully move it towards the rear of the vehicle A N A re f P e D 4 4 g 2 A Ge i e 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 32 Close the cargo box With the help of assistant remove the transmission from the rear of the vehicle as shown Transmission Disassembly NOTE Refer to the exploded view at the end of this chapter as a reference 1 Place the transmission in Reverse before disassembly Drain and properly dispose of the transmission lubricant see Chapter 2 Remove the shift cable from the bellcrank Remove the bellcrank nut A and bellcrank Remove the E clip C that retains the gear selector switch D and remove the switch Remove the sector cover bolts E and remove the sector cover F NOTE Removal can be aided by using your thumbs to press down on the shafts while pulling the cover up with your fingers 10 Remove the detent star H Note how the detent star fits onto the splined shaft with the raised edge facing outward for reassembly Remove the lockout disc 1 Note the raised edge facing outwa
20. onnect the brake switch harness located below the outer PVT cover Using a 3 8 socket extension and ratchet remove the 9 screws retaining the outer PVT cover Remove the cover from the vehicle Remove the drive belt drive clutch and driven clutch see Chapter 6 Clutching Using a Phillips screwdriver remove the 3 screws retaining the inner PVT cover to the engine Using a 3 8 socket and ratchet remove the 5 screws retaining the inner PVT cover to the transmission and remove the cover 10 Using a 15mm socket ratchet and wrench remove the upper fastener from the rear shock on each side 11 Remove the rear brake lines from the rear upper A arm retainers 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 12 Using a 15mm socket ratchet and wrench remove 15 Remove the shift cable from the transmission bell the through bolt retaining the rear upper A arm to the crank and disconnect the gear selector switch bearing carrier on each side 16 Using a 3 4 open end wrench loosen the lower jam 13 Remove the rear drive shafts from each side of the nut on the shift cable and remove the shift cable from transmission by pulling out sharply on each shaft the mount bracket 14 Remove the exhaust springs retaining the exhaust 17 Disconnect the rear differential solenoid silencer and remove the silencer from the vehicle 18 Dis
21. operly align all components Input Shaft Shift Fork Rail Reverse Shaft needle Bearing 33T Gear Reverse Shaft Washer Retaining Ring Engagement WV se Y Input Shaft Dog Bearing Q Bearing Silent Chain Bearing 8 18 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 NOTE ease assembly use plastic strap to 6 With all the components in the correct position install hold the shift forks and the shift drum together the 4 output gear assembly retaining screws Apply during assembly Loctite 242 to the threads of the screws Torque the screws to specification NOTE If the transmission is in gear place the transmission in Neutral 5 With the gearcase on it s side hold the gear cluster assembly and output assembly together Carefully install each shaft into their respective recess in the gearcase e Ze Output Gear Retaining Screws 1 8 12 ft Ibs 11 16 Nm 7 Install the oil deflector shield into the gearcase Apply Loctite 242 to the threads of the screws Torque the screws to specification e T Oil Deflector Retaining Screws 20 30 in Ibs 2 3 3 4 Nm 8 19 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 8 Install the rear drive differential an
22. otches through the locking screw hole KT Snorkel Locking Screw 8 12 ft Ibs 11 16 Nm 13 With the snorkel shaft properly installed remove the 4 Torx screws and remove the output shaft 10 Check the output shaft gear backlash again by feel If the output shaft lash appears to be too tight rotate the snorkel shaft counterclockwise to the next notch 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 D Inspect the shift drum for any damage or wear Inspect the splines of the shift drum Replace the O ring on the 1 Assemble reverse shaft and input shaft if previously end of the shift drum and lubricate it before assembly disassembled see illustrations Transmission Assembly Bearing Washer Needle D Bearin N Retaining Ring N K amp Retainin CH 9 Retaining Ring Ring Gear 38T Sprocket gt Washer Engagement 3 Stretch the silent chain on a flat surface and measure the length of 8 pitches in minimum of three places q N Washer on the chain Replace the chain if the measurement P is longer than the service limit Needle Bearing ee inf ee Silent Chain Service Limit 8 pitch 3 090 7 849 cm Reverse Shaft 4 The shift drum reverse shaft input shaft shift fork rail and output gear assembly must be installed at the same time to pr
23. r 36T Disconnect 36 1 Input Shaft 35T XP HD Input Shaft 31T CREW 84 6 Gear Assembly 37 1 Silent Chain 85 6 Dowel Pin 38 1 Compression Spring 86 1 Cover 39 2 Shift Fork 87 6 Screw 40 2 Compression Spring 88 1 Solenoid 41 1 Rail Shift Shaft 89 2 Washer Fender 42 2 93 2 Bearing Needle 43 1 Torsion Spring 94 1 Lockout Disc 44 1 Cam Chain Tensioner 99 1 Vehicle Speed Sensor 45 1 Shoe Chain Tensioner 100 1 O Ring 46 1 Shift Drum 101 1 Brake Disc Hub Assembly 47 1 Gear Sector 31T 102 1 Washer Fender 48 1 Shift Shaft 103 1 Screw 49 1 O Ring 104 1 Vent Tube 8 27 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 TRANSMISSION EXPLODED VIEW 2012 RANGER XP HD 800 PN 1332961 RANGER CREW 800 PN 1332977 25 30 ft lbs 34 41 Nm 23 27 ft Ibs Se 81 37 Nm vz SS S dy SEA D 4 10 15 ft lbs 14 20 262 Ze 20 30 in lbs 8 12 ft Ibs Eey 2334Nm 11 16 Nm 0 242 242 NS D e P Se 8 Q d x A 7 Ga d amp a 8 12 ft Ibs AX 11 16 NM 2 e 4 Y Se 4 10 14 ft Ibs i 14 19 Nm 4 A Pe amp lt e e Y lt 23 27 ft Ibs 31 37 9 gt AY P Bi vk e 8 12 ft Ibs BET e 11 16 Nm
24. rd for reassembly Remove the shift shaft J detent pawl K and the shift gears and M IMPORTANT Note the timing marks on the shift gears L and M for reassembly purposes 8 11 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4X4 11 Remove the bolt and washer retaining the brake disc 14 Remove the cam chain tensioner spring Slide the assembly to the transmission and remove the disc cam chain tensioner shoe P pins and cam chain tensioner cam N from the assembly 12 Remove all the transmission cover bolts Using suitable pry bars remove the cover using the designated pry points indicated by the black arrows in the illustration below Tap cover with soft face hammer to remove 15 Remove the differential gear R and chain by gently prying underneath or tapping the differential gear from the opposite side until it tips toward the output gear S The differential gear is connected to the shift fork and must slide backwards to clear the fork arms once the chain is removed CAUTION Do not pry on case sealing surfaces Use only the designated pry points on the transmission 13 Note location of chain tensioner cam N If fully extended chain is worn beyond service limit and should be replaced along with the chain tensioner shoe 16 Using a T20 Torx driver remove the screws that secure the oil deflector T
25. ris Sales Inc TRANSMISSION 4 4 NOTES 8 30 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
26. rom each shaft 27 Disassemble the other end of the reverse shaft Remove the retaining ring washer gear and needle bearing from the reverse shaft see Figure 8 2 Bearing Washer K N Needle DG K Bearing N Retaining Le gt Rin Ca 5 amp Retaining Retaining a4 Ring N ang e x Gear 38T Sprocket x N CON Engagement Dog Washer Washer Reverse Shaft Needle Bearing Figure 8 2 28 Remove the washer retaining ring and engagement dog from the reverse shaft see Figure 8 2 29 Remove the retaining ring washer 38T sprocket and needle bearing from reverse shaft see Figure 8 2 8 14 30 disassemble the shift fork rail remove the snap ring W from the end of the shift rail on either side CAUTION Use caution when disassembling the shift rail The compressed springs on the shift rail may pop off causing eye or face injury Snorkel Shaft Removal Disassembly 31 Using a T27 Torx driver remove the snorkel tube locking screw located inside the gearcase 32 Remove the seal from the snorkel shaft to access the snorkel tube for removal Seal Removed 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 33 Using the Snorkel Tool PA 50231 loosen and 36 Remove the snap ring and shim retaining the bearing remove the snorkel tube and shaft assembly in the snorkel tube Snap
27. upper fasteners to specification 28 Carefully lower the vehicle to the ground and reinstall eS T the side storage container and seat Rear Upper Shock Bolts 30 ft Ibs 41 Nm 19 Install the shift cable onto the mount bracket 20 Install the shift cable onto the transmission bell crank end and secure with the outer washer and clip Le 8 24 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc TRANSMISSION 4 4 TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered Shift cable adjustment condition Idle speed throttle cable routing PVT clutch alignment Transmission lubricant type quality Drive belt deflection where applicable Loose fasteners on sector gear cover Worn rod ends clevis pins or pivot arm bushings Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting the shift cable end from the transmission bellcrank Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is outside the transmission If transmission problem remains disassemble transmission and inspect all gear dogs for wear rounding or damage Inspect all bearings cir
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