How to Replace Polaris Ranger 800 Front Wheel Bearings

A worn wheel bearing on a Polaris UTV is a problem that if left unattended, can lead to a damaged wheel hub and half shaft, both expensive to replace.

Watch the video above and follow the steps below to replace the front wheel bearings on a Polaris Ranger 800 Crew.

NOTE: We worked on a Polaris Ranger 800 Crew, but the process is the same or similar for most Polaris UTV makes and models.

Tools and Parts Needed – Polaris Ranger Crew Wheel Bearing Replacement

Tools

  • Ratchets and extensions
  • 13mm, 15mm sockets
  • Torque wrench
  • Circlip pliers
  • Press
  • Bearing driver set

Polaris Ranger Crew 800 front wheel bearing change

Removing Polaris Ranger 800 Crew Front Wheel Bearings

Step 1. Raise the front of the Ranger and support it on axle stands. Make sure the axle stands are positioned under the frame, not the floor panels, then remove the front wheels.

NOTE: Don’t work on your side-by-side or any other vehicle using only a jack. Always make sure the vehicle is properly supported on axle stands.

Step 2. Remove the two 15mm bolts from the brake caliper mounting bracket, then slide the caliper and bracket off the brake rotor. Use a zip tie or bungee cord to hold the caliper out of the way so it isn’t suspended by its brake line.

Polaris Ranger Crew front calipers

Step 3. Pry the cap off the wheel hub, then remove the cotter pin, the castle nut and the two cone washers from the end of the driveshaft. Pull the hub from the steering knuckle.

Polaris Ranger Crew front wheel bearing removal

Step 4. Remove the cotter pin, steering arm bolt and two washers from the steering knuckle. The bolt has a 13mm head at the top and a 15mm nut at the bottom. 

Polaris Ranger 800 front steering arm

Step 5. Remove the two 13mm pinch bolts from the steering knuckle that hold the ball joints in place. Pull the ball joints free from the steering knuckle and remove the knuckle.

Polaris Ranger Crew ball joint

Watch the clip below to see the steering knuckle removal segment of our Polaris Ranger 800 Crew front wheel bearings video.

Installing Front Wheel Bearings in a Polaris Ranger 800 Crew

Step 6. Remove the retaining circlip from the steering knuckle.

Polaris Ranger Crew 800 steering knuckle circlip

Step 7. Position a socket or piece of pipe (with a diameter that’s wider than the wheel bearing but narrower than the steering knuckle) over the steering knuckle.

Step 8. Position a bearing driver (with a diameter that’s as wide as the outer race of the wheel bearing but narrower than the steering knuckle) over the wheel bearing, and press the old wheel bearing out of the knuckle and into the piece of piping.

Polaris Ranger Crew front wheel bearing removal

Step 9. Thoroughly clean the steering knuckle and coat the housing where the new wheel bearing will sit with red threadlocker

Step 10. Position a bearing driver over the outer race of the wheel bearing, then press the new wheel bearing into the knuckle.

Polaris Ranger 800 wheel bearing installation

Step 11. Install a new retaining circlip into the steering knuckle. 

NOTE: Don’t reuse the old circlip, as it'll have lost some of its tension and may come loose from the knuckle.

Watch the clip below to see the wheel bearing installation segment of our Polaris Ranger 800 Crew front wheel bearings video.

Rebuilding Front Suspension in a Polaris Ranger 800 Crew

Step 12. Grease the driveshaft splines, and slide the steering knuckle back over the driveshaft.

Polaris Ranger Crew 800 ball joints

Step 13. Push the upper and lower ball joints back into the steering knuckle, then reinstall the pinch bolts and torque them to 23 foot-pounds.

Step 14. Reinstall the steering arm with the two washers and the mounting bolt to the steering knuckle, but don’t torque the mounting bolt yet.

Watch the clip below to see the steering knuckle reinstallation segment of our Polaris Ranger 800 Crew front wheel bearings video.

Step 15. Grease the inner and outer sides of the wheel hub, then slide it back over the driveshaft splines and into the steering knuckle.

Polaris Ranger Crew front wheel bearing change

Step 16. Reinstall the two cone washers onto the driveshaft splines with their raised centers facing outward.

Step 17. Reinstall the castle nut and torque it to 80 foot-pounds. 

PRO TIP: Have someone apply the brakes to stop the nut from rotating as you torque it.

Step 18. Install a new cotter pin and bend it as shown in the image below.

Polaris Ranger 800 front wheel bearing installation

Step 19. Reinstall the brake caliper and mounting bracket, then apply blue threadlocker to the two 15mm mounting bolts and torque them to 30 foot-pounds.

Step 20. Reinstall the brake line bracket on the upper A-arm with the Torx T25 bolt.

Step 21. Torque the steering arm mounting bolt to 40 foot-pounds, then install a new cotter pin and reinstall the cap over the wheel hub.

Next, replace the ball joints on the other side and you’re done.

Watch the video below to see the brake caliper and wheel reinstallation segment of our Polaris Ranger 800 Crew front wheel bearings video.

 

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