--------------------------------------------------------------------------------

I have an 04.5 400 with the AWD system (hilliard in front diff.). Recently it started having unlocking issues. If I am in reverse and spin the rear wheels the front will engage as normal but then when I put it in forward it remains engaged and is very hard to steer. If I turn off AWD and reverse a few feet it will unlock and evertything is normal again. If it engages in forward it will unlock normally. Also I had it on the hoist today and with the AWD switch off the front will engage although at a higher speed (10+ mph) than with the AWD on, is this normal? With AWD on it will engage the front almost immediately. I changed the fluid with no improvement, old fluid was dark but no moisture in it. Today one of the front outer CV joints broke and came apart, would this have been caused by the front remaining engaged more than it is supposed to?

 

I`m not 100% sure but to me it sounds like the spring around the hillard is weak, if it is weak when running the quad down the road in 2wd the front will lock in and cause the quad to suddenly pull to 1 side also will it will act like your does when disengaging the awd

 

Mine was acting kind of funky like that, some times engaging rite away some time not, some times not disengaging. I changed the fluid to the new demand drive fluid from polaris and its been fine since. I actually changed the fluid twice as it was a 32 oz bottle and it only holds 8 or so ounces so I drained it, filled it up, rode it around for a few minutes drained it again and filled it up.

 

Try changing the fluid again like mentioned, hopes its not a broken Plastic Roller Cage,fairly common down fall of the newer centralized AWD system.

 

I had the same case with the Sportsman 500 H.O. After replacing all the fluids were working properly. We need to replace fluids and that after checking the level after a little driving.

 

I think he said "I changed the fluids with no improvement".

I'm betting that it's that wonderful plastic roller cage.

 

Don't get me wrong, the AWD works great and I have power at all 4 wheels when I need it, it is the unlocking that is the problem. If the cage was broke would I still have power to all 4 wheels?

 

Sounds like you should be OK to me.

 

Your not "OK" if it is staying engaged and it is tough to steer. When the system is working correctly, AWD will engage with a slight slippage of the rear wheels, and will disengage shortly after the rear wheels regain traction. Doesn't matter whether it's the rear wheel slipped when going in reverse or forward... it has to DISENGAGE.. or it's not right... period.

If you changed the fluid, put the correct fluid in, and put the correct amount of fluid in it and it is still staying engaged, then something is wrong.

It could be the armature plate, a bad roller(s) or a couple other things... one of which could be a cracked/bad roller cage. There's a bunch of junk that can go wrong with a Hilliard.

Good luck.

 

If you use the "Search" on this site, the symptoms of a broken Plastic Roller Cage can vary and be very erratic, some have awd in forward but not reverse,others have awd in reverse but not foward,some cant get the awd to come on,others can,t get the awd to turn off.

If clean fluid does not help,you will have to look inside the front diff, its not as a big job as you would think.

If it is the Roller Cage,apparently "John Deer" makes a much stronger "metal" one that will work on the Polaris. Also a a company called "DragonFire" makes them for the Polaris RZR, which I think uses the same Plastic Roller Cage on there ATVs.

Did your ATV get the ECM recall done, if that think acts up all sorts of screwy things happen. http://forums.atvconnection.com/pola...cm-recall.html

http://www.atvsource.com/articles/pr...r_products.htm

here is another good read about it. http://forum.highlifter.com/john-dee...-m1942879.aspx

Looks like this