Remove the whole DD assembly. It is fast, and easy. Plus with the DD out of the sled you can get the cover back on the correct way.
When I did mine the first time, I just pulled the cover and replaced the bearing. The cover would not "slap" back on it needed to be drawn in with the cover bolts. Which is not correct I learned after talking to BDX. THe said to loosen the 16mm bolt that goes threw the brake side of the jackshaft. And try to fit the cover so it would "slap" on. Or just pull the whole DD out which is what I did and like I said it is easy and fast.
To pull the DD
Mark with a pencil around the rear axle washer (this will give you an idea of where to reset the track tension) Loosen the rear axle on the rear skid, loosen up the track tension adjusters.
Remove the secondary, make sure to see if you have any alignment shims behind the secondary. They slide on the shaft of the DD
Remove the metal plate by the footwell, it has 4 torx head bolts. 2 are under the footwell of the tunnel. 2 are by the rear of the secondary
Remove the lock nuts around the DD where it bolts to the bulkhead.
Remove the 16mm bolt using a long extension going threw the break side of the jackshaft. You can just loosen the bolt all the way do not need to pull the bolt out of the jack shaft.
THen you can pull the DD assembly out of the chassis
Once the DD is out
Drain the fluid, using the drain plug
Remove the torx cover bolts on the DD cover
The gear with the "bad" bearing will just pull out by hand.
You can mark where the gears meet with eachother with a sharpie or paint marker to make sure you put them in the way they were. Not sure if this matter or not.
Use a bearing puller to remove the old bearing.
Use a press or a bench vise with a peice of board on each side of the teeth of the vice so you do not scare the bearing or the gear. I do not like to beat bearings back on to the shaft. Easy to do with a bench vise.
You can pull the planetary out by removing the "c-clip" and clean and inspect it.
Put the planatary and the c clip back in. And put the gear with the new bearing in. Install cover which should slap right on meeting with the DD case.
Refill the DD with oil. (Or can wait till the DD is in the Chassis and tip the sled on its right side, fill the DD threw thew fill bolt. Install bolt, put sled back on its ski's and you can remove the filler bolt (top one) to check the oil level. The oil level should be to the bottom the the bolt filler hole)
Put some grease on the splines of the output shaft where it meets the track shaft.
Put the DD back into the chassis. Align the track shaft with the DD output gear, turn the shaft that goes to the secondary slowly to get the splines to meet up while pushing in on the DD case
Install the lock nuts
Install the cover with the 4 trox bolts.
Install the 16 mm bolt
Put the secondary back on, note the alignment shims.
Set you track tension and tighten rear axle.
If you want you can Re align the secondary. I check my alignment after removing the DD and it was spot on where is was before removing the DD...
Replacing the bearing is very easy to do, the whole job will take around maybe and hour to do you first time.
I used the Arctic Cat DD oil and put 200 miles on it and the oil looked like ****. I am going to try the BDX DD oil this time to see how that looks after a few hundred miles.
