I'll try that, just got it back together and no4wd on right side, it either stays on or off. i'll try 144inlbs

 

Tried 144 inlbs, of course it didn't work, but I would rather have it unlocked all the time than locked. I do have some pretty good pitting on the rollers in the cage, don't know if that would do it. Seems like it would grab a little. I'm getting real tired of messing with it over and over. Left side works great. I've been using mercon v as per manual. Any ideas would be appreciated, I've run out of ideas and patience.

 

Look real close at the face of the coil sleeve and the inner strut pole for any wear. Also again if the coil sleeve face and inner pole are not flush the plate can't get a good hold. Another thing you can do is have the key on,in awd mode and in gear and then see if the plate will pull from your fingers and stick to the the sleeve.If you can easily move the plate around on the sleeve while it has a magnetic pull,then the coil may be too weak even if it ohms out close to 25 ohms resistance. Plus I'd use Demand Drive Plus hub fluid.

 

I'll check, thanks.

 

It has a pretty good pull, not enough to pull it out of my fingers. according to manual the inner sleeve is .025 in frm outer. Is that right

 

Just look at this example again. Plus an example of a strut that's really damaged..Straight edge must be flush or no more than .001 between the coil sleeve and the inner pole of the strut. Plus if you've changed the plate,replaced any rough feeling bearings, the hilliard is rotating ok,plus torqued down properly,only thing left is the coil,sleeve or any damage to the inner pole of the strut keeping the awd from working properly.

 

Struts in good shape, I'd have to take it apart again but I think there's more than .001. Do I drive it out from inside to get flush again? It's closer to .030 Damn. rechecked the manual-it's .025mm [.001]. I think I have made every mistake possible. Please tell me their is a $15.00 tool that will pull the inner back out without taking CV and all out again.

 

You can't move the sleeve! It's set in blue rtv silicone and trying to move it,if it even will move,won't last as it will move again.Problem is to set one properly you have to remove it. In removing it 9 times out of 10 times you break the coil.. Might as well replace the coil sleeve and coil and do it right. Here's some good pics of this courtesy of a member of Polaris Atv Forums.AWD Hubstrut Hilliard Clutch Troubleshooting/Diagnoses - Polaris ATV Forum

 

McAfee used to always tell me that polarisatvforums.com was a risky site to visit but now it doesn't. I don't think there ever really was a problem but It's nice to know they aren't worried about it. Now they just don't know anything about it. That was the best description of fixing the strut that I've ever seen.

 

It is strange.. My old computer that I had Avast on had a warning for their site. I've got McAfee on my new computer and not a peep.. I wondered about that too...