2001 Bombardier Traxter XT XL ATV Repair Manual

Section 06 DRIVE TRAIN Subsection 01 (TABLE OF CONTENTS) VMR2001_065_06_01ATOC.FM 06-01-1 TABLE OF CONTENTS 0 FRONT DRIVE ........................................................................................................................ 06-02-1 FRONT DRIVE SHAFT ....................................................................................................... 06-02-2 FRONT DIFFERENTIAL ...................................................................................................... 06-02-3 FRONT PROPELLER SHAFT .............................................................................................. 06-02-10 KNUCKLE ........................................................................................................................... 06-02-12 WHEEL BEARING .............................................................................................................. 06-02-12 REAR AXLE ............................................................................................................................ 06-03-1 RIGID AXLE AND PROPELLER SHAFT ............................................................................. 06-03-1 RIGID AXLE ........................................................................................................................ 06-03-2 RH AXLE.......................................................................................................................................... 06-03-3 LH AXLE ............................................................................................................................. 06-03-3 REAR PROPELLER SHAFT................................................................................................. 06-03-4 REAR HUB .......................................................................................................................... 06-03-4 REAR DIFFERENTIAL ........................................................................................................ 06-03-5 REAR DIFFERENTIAL OIL LEVEL ...................................................................................... 06-03-6 REAR DIFFERENTIAL OIL REPLACEMENT ................................................................................ 06-03-6 REAR DIFFERENTIAL ........................................................................................................ 06-03-6

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) VMR2001_055_06_02A.FM 06-02-1 FRONT DRIVE 0                                                   

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) 06-02-2 VMR2001_055_06_02A.FM FRONT DRIVE SHAFT Removal Raise the front of vehicle, support it securely on jack stands and remove front wheel(s). Remove wheel cap no. 13, cotter pin no. 12, castellated nut no. 11, flat washer no. 10 and O-ring no. 21. CHECK THE O-RING FOR DAMAGE, REPLACE IF NECESSARY Remove cotter pin and castellated nut from upper and lower suspension arms. 1. Castellated nut 2. Cotter pin 3. Lower suspension arm 4. Upper suspension arm Separate knuckle no. 8, with hub and brake disc no. 9, from lower and upper suspension arms. Separate knuckle from the drive shaft no. 7 or no. 14. Pull drive shaft out of differential no. 1. NOTE: Pull drive shaft strongly. Inspection Inspect the condition of boots. If there is any damage or evidence of leaking lubricant, replace them. Refer to Drive Shaft Boot section. Installation Apply grease (P/N 293 550 019) to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove. 1. Stop ring Insert the other end of drive shaft in the knuckle and install the knuckle, with hub and disk brake, to the lower and upper suspension arm. Torque the castellated nuts to 75 N•m (55 lbf•ft) and install a new cotter pin. Install the flat washer and torque the castellated nut on the drive shaft end to 140 N•m (103 lbf•ft) minimum. Install a new cotter pin and the wheel cap. Reinstall the front wheel(s) and torque the four nuts to 75 N•m (55 lbf•ft).          

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) VMR2001_055_06_02A.FM 06-02-3 Drive Shaft Boot Removal Remove: – clamps from rubber boot using boot clamp pli- ers (P/N 295 000 069 and 295 000 054) – large end of the boot from plunging joint or CV joint. Move apart circlip and pull out the shaft from bearing. Do not remove circlip. 1. Circlip 2. Shaft Remove boot from drive shaft. Inspection Check bearing in plunging joint or CV joint. If bearing is hard to move, change plunging joint or CV joint. Check circlip for damage, change as necessary. Installation For installation, reverse the removal procedure. Paying attention to the following details. Insert boot, do not forget the small clamp. Insert shaft and push firmly. Pack bearing area with grease (including with the new boot kit). NOTE: Do not use an other grease. FRONT DIFFERENTIAL Removal Raise front of vehicle, support it securely on jack stands and remove front wheels. Remove: – skid plate – winch protector – front bumper – inner fender. Refer to BODY for the proper instructions. On LH side, remove: – wheel cap no. 13 – cotter pin no. 12 – castellated nut no. 11 – flat washer no. 10 – O-ring no. 21. On front side, remove: – differential mounting bracket bolt no. 4 – front mounting bolt no. 3 – rear mounting bolt no. 5 – differential bracket no. 22 – mounting bracket no. 2. 1. Front mounting bolt M10 x 200 2. Differential mounting bracket bolts 3. Bracket 4. Rear mounting bolt M10 x 60        

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) 06-02-4 VMR2001_055_06_02A.FM On RH side, remove drive shaft. Unscrew propeller shaft bolt no. 19. Differential side only. Remove rubber bellows no. 15 on the top from the front differential. Pull differential forward then separate RH propeller shaft no. 7 from differential. Remove front differential by the RH side. Separate LH drive shaft no. 14 from differential. Inspection Turn front differential gear with a finger; it should turn smoothly. Replace if necessary. With drive shafts installed, check backlash and ax- ial play. Backlash Procedure NOTE: The backlash is the last procedure when the differential is rebuilt. Insert the measuring attachment tool into the differential and secure it with a screw. NOTE: The measuring attachment tool could be not available immediately. In such a case, use a drive shaft to replace the measuring attachment tool. Place the other end of measuring attachment tool in vise. Install the measuring attachment lever (P/N 529 035 665) onto the end of pinion gear and secure it with the “T” bar fastener. Install an dial gauge. The indicator probe touching the lever of measuring attachment lever. Gently lift the lever attachment until some resis- tance is felt. Note the indicator reading. An acceptable backlash is in the range from 0.102 to 0.356 mm inclusive (.004 to .014 in). If backlash is out of specifications, disassemble the differential and change ring gear carrier shims. See PINION GEAR AND RING GEAR CARRIER RECENTERING below.   

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) VMR2001_055_06_02A.FM 06-02-5 Disassembly Ring Gear Carrier/Ring Gear Removal To change ring gear carrier no. 22 or ring gear no. 23: – Unscrew the drain plug no. 24 and empty differential. – Unscrew the TORX screws no. 25, then separate half housings. – Extract ring gear carrier with ring gear out of half housing. – Unscrew Allen socket screws no. 26 then separate ring gear from ring gear carrier. To assembly, reverse the removal procedure. Pay- ing attention to the following details. NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See PINION GEAR AND RING GEAR CARRI- ER RECENTERING below. Verify condition of half housing seal no. 27. Change seal if necessary. Check all bearings and all oil seals. Change them if necessary. Pinion Gear Removal Remove oil seal no. 28. Unscrew the pinion nut no. 29. Use the differential spanner socket (P/N 529 035 649). Remove the bearing no. 30 at the same time as the pinion gear no. 31. NOTE: The pinion gear and bearing can be easily removed using the following suggested tool: – pipe 3-1/2” dia. x 5” (1) – screwed rod M10 x 1.25, 7” in length (1) – nut M10 x 1.25 (3) – flat bar (1). To install, reverse the removal procedure. Paying attention to the following details. Check O-ring no. 32 for damage. If so, change it. Install the shim no. 33 then the ball bearing. NOTE: If ring gear carrier, pinion gear, ring gear, housing or bearing is (are) changed, recenter the ring gear carrier in the housing before final assembly. See below. Install the nut and a new oil seal. Pinion Gear and Ring Gear Carrier Recentering NOTE: All measurements require great care and absolute cleanliness if accurate results are to be obtained. First; center pinion gear. Install pinion gear into housing. Measure distance between mount surface and the top of pinion gear. This is measure “A”.  

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) 06-02-6 VMR2001_055_06_02A.FM Remove pinion and install ring gear carrier with ring gear installed. Measure distance between mount surface and the top of ring gear. This is measure “B”. Subtract measure “B” from measure “A”. Note this result “C”. A - B = C Remove ring gear carrier then install pinion gear into housing. Measure distance between mounting surface and the pinion shim surface. This is measure “D”. Remove pinion gear then measure the distance between mount surface and bearing surface. This is measure “E”. Subtract measure “E” from measure “D”. Note this result “F”. D - E =F The difference between result “F” and result “C” is the pinion shims thickness. F - C = Pinion shims thickness. Determine the appropriate pinion shim using the following pinion gear shims kit (P/N 703 500 049). Install pinion, shims, bearing and pinion nut. Apply Loctite 243 to nut and torque to 98 N•m (72 lbf•ft). Check if pinion gear teeth and ring gear teeth are equal. After pinion installation, center ring gear carrier. Take the half housing with pinion gear. Measure distance between housing edge and the inner ring of bearing. This is measure “G”.   THICKNESS NOTCHES 0.25 mm (.010 in) 0 0.38 mm (.015 in) 1 0.51 mm (.020 in) 2 0.56 mm (.022 in) 4 

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) VMR2001_055_06_02A.FM 06-02-7 Measure the other half housing between housing edge and the inner ring of bearing. This is measure “H”. Measure the edge of half housing. This is measure “J”. Subtract the measure “J” from measure “H” then add this result to “G”. Note this result “K”. G + (H - J) = K (housing inside length) Measure ring gear carrier length. This is measure “L”. Measure the distance between the end of ring gear carrier and the bearing shoulder. Note this measure “M”.     

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) 06-02-8 VMR2001_055_06_02A.FM Take the same distance to the other end. This is measure “N”. Add measure “M” from measure “N”. Subtract this result from measure “L”. Note this result “P”. The result “P” is the length of ring gear carrier between bearings. L - (M + N) = P Subtract result “P” from “K”. At this measure subtract the clearance 0.127 mm (.005 in). This is the shim thickness. K - P = X - 0.127 mm (.005 in) = shim thickness. Determine the appropriate shim using the following ring gear carrier shims kit (P/N 703 500 050). Distribute total shim thickness between both end of ring gear carrier to obtain specified backlash between ring gear and pinion gear. THICKNESS NOTCHES 0.25 mm (.010 in) 0 0.38 mm (.015 in) 1 0.51 mm (.020 in) 2 0.64 mm (.025 in) 3 0.56 mm (.022 in) 4 

Section 06 DRIVE TRAIN Subsection 02 (FRONT DRIVE) VMR2001_055_06_02A.FM 06-02-9        

2001 Bombardier Traxter XT XL ATV Repair Manual

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