Transmission Service; Transmission Removal / Service Notes; Transfer Case Disassembly - Polaris Ranger RZR 800 Manual

TRANSMISSION

TRANSMISSION SERVICE

Transmission Removal / Service Notes

The engine, transmission and rear differential are bolted
together as a unit. Removal of the transmission is not possible
without removing the engine and differential.
The shift housing cannot be removed without first
disassembling the transfer case.
NOTE: Refer to the "Engine Removal" section in
Chapter 3 to remove the engine and drivetrain.

Transfer Case Disassembly

IMPORTANT: Shift housing repairs are not possible
without performing transfer case disassembly. Read
and understand all instructions before beginning
disassembly.
NOTE: Exploded views are located at the end of this
chapter for additional information.
1. Place the transmission in the neutral position.
2. Drain both the transfer case and transmission case halves.
Transfer Case
Drain Plug
8.4
Transmission Gearcase
Drain Plug
3. Remove the (7) fasteners retaining the transmission to rear
gearcase mount bracket.
Note the number or
thickness of shims for
reassembly purposes.
4. Remove the connector tube bolts securing the rear gear case
and transmission transfer case.
5. Inspect the driveshaft splines for wear and the O-rings for
damage. Replace if found to be worn or damaged.
6. Remove the LH front isolator mount bracket. Refer to
Chapter 3.
7. Remove the screws from the transfer case cover and
remove the cover (note position of the longest screw #4).
1
8
3
5
6
4
2
7