2005-2007 Polaris Ranger 500 service manual, Page 223Get this manual
FINAL DRIVE 16Remove the other output hub (K) from the main gearcaseInspect the inner bearing (L) for wearIf there is excessive wear, replace bearing as needed19Install new seals into the gearcase housing and use new Orings for the gearcase input and output covers
17Remove the input cover (M), bearing (N), and the pinion gear (O)Inspect the pinion gear (O) for chipped, broken, or missing teethReplace the input cover O-ring
Gearcase ReassemblyInspection
1As mentioned in the disassembly section, replace all Orings, seals, and worn components2Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface3Inspect bearings on output and pinion shaftsTo replace, press new bearing on to shaftNOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feelWhile rotating bearings by hand, inspect for rough spots, discoloration, or corrosionThe bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side4Install pinion shaft, bearing, and input cover with new oring and torque bolts to 17 ftlbs(23 Nm)