How to Remove Rear Axle on Polaris ATV

Rear axles are vehicle parts that transmit power between the differential and driving wheels. They play a role in the ATV’s transmission and suspension system, meaning they should be immediately replaced or fixed if they are malfunctioning. If you face any type of trouble, we will teach you how to remove rear axle on Polaris ATV.

Since the Polaris rear axle removal can be complicated and requires precision, it's best to follow our expert step-by-step guide. We will explain the entire process in detail so you do not miss any important steps.

How to Remove Rear Axle on Polaris ATV

When it comes to maintenance and repair, it’s always best to leave it to the professionals and look for the best Polaris ATV repair services. However, if you know your way around an ATV and have the right tools, you might be able to do it yourself and save some time.

As it is a delicate process, you should do it by following our instructions. Each step is important, from gathering the right tools to putting the new axle in place.

1. Gather the tools for replacing rear axle on Polaris ATV

Before we jump off to the steps on how to change rear axle on Polaris Sportsman, we need to ensure you have all the needed equipment to get the job done efficiently and safely. 

Generally, you will need the following tools:

• Floor jack and jack stands for lifting the ATV
• Socket set with various sizes to remove and install bolts
• Torque wrench for torquing the nuts to the manufacturer’s specifications
• Breaker bar to loosen tight bolts
• Grease for lubrication

2. Preparing the ATV for rear axle removal

After you have all the necessary tools within hand’s reach, it’s time to take your Polaris ATV, park it on a level surface, and engage the brake. Continue by taking the floor jack or ATV stand and using it to elevate the back of the vehicle. Secure your ATV with jack stands.

3. Remove the tires

The next thing you should do is take a lug wrench and loosen one lug nut at a time. When they are all loose, you can remove them entirely and take off the rear wheel.

4. Break loose the central nut

Put the wheel away and remove the cap from the wheel hub assembly to access the castle nut and cotter pin. Use a needle nose to straighten the cotter pin so you can remove it. You might also need a hammer to do this. Don’t use too much force, or you might break it, and you will have to find a new one to replace it.

Use an impact wrench to break loose the central nut of the wheel hub assembly. You might also need to put a screwdriver into the rotor’s cooling holes to prevent it from spinning as you attempt to unscrew the nut.

5. Break the hub assembly free

Next, you should remove the three nuts holding the brake drum – the two lining nuts and the caliper piston nut. The two lining nuts are located on the sides, while the caliper piston nut is at the top. If they are too tight, you can use a hammer to lightly tap on the nut so you can remove it.

In addition, you should take out the two bolts on the brake caliper. Remove the brake caliper carefully without detaching brake lines and hoses. Put the brake caliper on the side so it doesn’t get in the way. 

Use the opportunity while the brake caliper is removed to check your brake pads. If they are showing signs of wear and are not the recommended thickness, you should change the brake pads on your ATV.

Furthermore, you should remove the entire hub assembly from the axle shaft. When you are done, remove the rubber bushings on each side. If they are loose enough, you can take them out with your hand; if not, you can use a flathead screwdriver and gently push them out. Ensure you are holding the hub assembly while you’re removing the second bearing, because it, along with the inserts, keeps it attached.

6. Get the axle out

There are different types of axles, such as semi-floating, full-floating, and three-quarter floating axles. Depending on the type, the next step on how to remove rear axle on Polaris ATV is detaching the axle. Typically, all you need to do is remove the retaining clips or snap rings. Then, you will be able to gently tap and slide the axle out of the differential.

7. Install the new axle bearings and put all components back together

Before installing the new axle, we recommend using grease on all parts. When installing the new axle into the differential, ensure it is completely and properly positioned.

Finish by putting all components back together in the reverse order of this guide and performing a final inspection. Check to see if everything is accurately torqued and test the brakes before driving your ATV.

An expert note: Generally, the process is the same for almost every Polaris ATV. So, if you are wondering how to replace rear axle Polaris Sportsman 500, Phoenix 170, or another model, you can do it by following our steps.

Conclusion

Many off-road vehicle owners need to know how to remove rear axle on Polaris ATV. The entire process can be divided into several main phases, including preparing the vehicle, removing the wheel, disassembling brake components, removing the old rear axle, and installing the new one. If you want professionals to replace your rear axle, our Wickham Tractor Co. service team is here for you.