Have any of you guys had this happen before. Any suggestions? The right hub works, but the left isn't. I have had it happen before where the electrical connection that goes to the hub has gotten corroded. I just haven't checked it yet. Is there any parts internally on the hub that could break and thus leave it unusable?

 

Yes, there are, but I would check the connection if that happened before.
If that is the problem, go to Radio Shack, NAPA or other parts store, and get 'Dielectric Grease' also called 'Electrical Contact Grease' Coat both parts of the connector with a dab of the stuff, and re-connect. That should prevent corrosion for a long time.

Farmr

 

This could happen from low hub fluid, water in the fluid, bad connections at the switch or the plugins or the magnetic coil on the strut could be bad.

Scrambler Pics

 

try changing the fluid first, if that doesn't help use a tester and make sure your getting a signal to the hub. If your getting a signal and it still won't engage then it's time to do a little investigation inside the hub. I blew a hub out plowing with my 400 xplorer, in my case it was mechanical failure.

 

Lovemud,
What actually "blew out" inside the hub. I am actually leaning towards that being the problem, but I'm really unmotivated to open it up unless I'm absolutely positive that is what it is. What part should I look for damage on?

 

It was under warranty at the time, so I just took it in. I heard a crunch and it wouldn't engage anymore. I've never been a fan of the reverse/awd override switch, on my 600 I wired it to a toggle switch so when I'm plowing it stays on all the time.
The last 4wd drive system I felt confident about was my 78' fj40 landcruiser - that thing could take abuse.....

It sounds like you need to take off the cap and see if there's pieces floating around.......

 

Mine is in the shop for the same thing.When I took it apart the armature plate had stripped and grooved the Hillard clutch cage.Had to take it in because I couldnt get the seal sleeve off and was affraid of messing the whole electrics up.the parts I figured up were around $150 hope he dont find much more bad.

 

Sometimes, and I don't know how often, if the cage is all screwed up, the bearings were loose. I say this, because I know of 2 cases where I found a loose bearing on a Polaris front wheel. I told the owner about it, and they did nothing, and within about a month, they had to replace the guts of their hubs.

Farmr