Big Boss 6x6 Suspension Parts: Upgrade, Repair & Maintenance Guide

The Big Boss 6x6 is a versatile utility vehicle known for its six-wheel drive and rugged capability. But like any off-road machine, its suspension takes a beating over time. Whether you’re looking to restore factory ride quality or upgrade for heavier loads and tougher terrain, knowing the right suspension parts for your Big Boss 6x6 is essential.

This guide covers the most common suspension components—shocks, springs, sway bars, bushings, and more—along with practical advice for selection and installation. By the end, you’ll know exactly what parts fit your machine and how to keep it riding smooth.

Types of Suspension Parts for the Big Boss 6x6

The Big Boss 6x6 uses an independent front suspension and a solid rear axle with leaf springs or coil-over shocks depending on the model year. Below are the key components you may need to replace or upgrade.

Shocks (Dampers)

Shocks control the rebound and compression of the suspension. Over time, they lose damping ability, leading to a bouncy ride and poor handling.

• Stock replacements: OEM-style shocks from Polaris or aftermarket brands like Monroe offer direct fit with standard damping.
• Upgraded gas shocks: Brands like Rancho or Bilstein provide better heat dissipation and consistent performance under load. Look for models with adjustable damping if you frequently change loads.
• Coil-over conversions: Some aftermarket kits convert the front suspension to coil-overs for better ride quality and adjustability. These are common among owners who add plows or heavy winches.

When selecting shocks, measure the compressed and extended length to ensure proper fit. Most Big Boss 6x6 models use a rear shock mounted at an angle—verify the mounting style (eyelet vs. stud) before ordering.

Springs and Leaf Springs

The rear suspension on many Big Boss 6x6 models relies on leaf springs. Over time, leaves can sag or break, especially with heavy loads.

• Stock replacement leaf springs: Direct fit from Polaris or aftermarket suppliers. Choose the same load rating as original (usually 3- or 4-leaf packs).
• Heavy-duty leaf springs: If you frequently carry heavy cargo or tow, consider an additional leaf or a heavy-duty pack. This reduces sag and improves stability.
• Add-a-leaf kits: A cost-effective way to increase load capacity without replacing the entire spring pack. Installation requires disassembling the spring pack and inserting the extra leaf.
• Coil springs (front): Some models use coil springs on the front struts. Stock coils can sag over years of use. Aftermarket coils from Eibach or Moog offer progressive rates for a smoother ride and better bottoming resistance.

Check the spring rate (pounds per inch) before buying. A higher rate supports more weight but stiffens the ride. For daily use with moderate loads, stick close to OEM specs.

Sway Bars (Anti-Roll Bars)

Sway bars reduce body roll during cornering. The Big Boss 6x6 has a front sway bar; some models also have a rear bar.

• Replacement bushings: The most common issue is worn sway bar bushings, which cause clunking noises. Replacing them with polyurethane bushings improves responsiveness.
• Upgraded sway bars: A thicker aftermarket sway bar (like from SuperATV or J&J) reduces body roll further, but can make the ride stiffer. Only upgrade if you experience excessive leaning.
• Disconnect options: For extreme off-roading, some owners install quick-disconnect end links for the front sway bar to increase articulation. This is less common on utility vehicles but useful for rock crawling.

Bushings and Ball Joints

Rubber bushings in the control arms and leaf springs wear out, causing loose steering and noise.

• Polyurethane bushing kits: Replace worn rubber with poly for longer life and tighter handling. They’re squeaky without lubrication, so apply grease during installation.
• Control arm bushings: Press-in style for the upper and lower control arms. Use a press or a shop to replace them.
• Ball joints: If you hear clunks when turning or hitting bumps, inspect ball joints. Replacement requires removing the knuckle and using a press. Choose greasable versions for longevity.

Steering Components

While not strictly suspension, tie rod ends and steering rack bushings affect how the suspension feels.

• Tie rod ends: Worn ends cause play in the steering. Replace both sides to maintain alignment.
• Steering bushings: On older models, the rack bushings wear, causing wobble. Replace with polyurethane for a more direct feel.

Compatibility and Model Years

Big Boss 6x6 models vary significantly by year. The suspension changed in 2014, when Polaris introduced a new chassis and independent rear suspension in some configurations.

• Pre-2014 models use a solid rear axle with leaf springs. Shocks are typically separate from the springs.
• 2014+ models may have independent rear suspension (IRS) with coil-over shocks. Verify your VIN or measure existing parts before ordering.

Always cross-reference part numbers from the manufacturer’s website or a reputable supplier. Many parts are shared with the Polaris Ranger or Sportsman, but the 6x6 has unique mounting points for the third axle.

Installation Tips

• Lift safely: Use jack stands under the frame, not the axles. The 6x6 is heavy.
• Torque specs: Follow factory torque specifications for control arm bolts and shock mounting nuts. Overtightening can damage bushings.
• Alignment: After replacing control arms or ball joints, get a front-end alignment. The 6x6 uses shims or eccentric bolts for camber adjustment.
• Bleeding brakes: If you remove the suspension, you may disturb the brake lines. Bleed the brakes after reassembly.

Buying Guide: What to Look For

1. Material quality: Chrome-plated shock shafts resist corrosion; powder-coated springs last longer.
2. Warranty: Reputable brands offer 1- to 5-year warranties. Avoid no-name brands.
3. Load rating: Match your typical load. Overbuilding leads to a harsh ride.
4. Adjustability: Adjustable shocks (e.g., with remote reservoirs) allow fine-tuning for load and terrain.
5. Price vs. value: A mid-range shock from a known brand is often better than a cheap unbranded one.

Common Problems and Solutions

• Rear sagging: Replace leaf springs or add an add-a-leaf. Check shackle bushings for wear.
• Front end wobble: Worn ball joints or tie rod ends. Also check wheel bearings.
• Clicking from front suspension: Loose sway bar end links or worn upper control arm bushings.
• Rough ride: Overly stiff shocks or under-inflated tires. Consider shock adjustment or softer springs.

Final Recommendation

For most Big Boss 6x6 owners, a practical approach is:

• Replace worn OEM shocks with high-quality gas shocks (e.g., Rancho RS5000) for improved ride.
• Use heavy-duty leaf springs if you regularly carry over 500 lbs in the bed or tow.
• Upgrade bushings to polyurethane for longer life and tighter handling.
• Stick with OEM-type ball joints and tie rod ends unless you need greasable versions.

Avoid over-upgrading if you use the vehicle for light chores. A stock ride with fresh shocks and bushings is usually sufficient. For heavy work or frequent trail riding, invest in adjustable coil-overs and heavy-duty springs.

Always verify compatibility with your exact model year. Measure existing parts and consult the manufacturer’s catalog. With the right parts, your Big Boss 6x6 will deliver years of reliable service.