Just wanted to post this to my orginal problem on the 4 wheel drive. After replacing the return spring (p/n 0402-999) I still discovered my problem was not fixed. After doing a little driveway plowing of snow, I heard this grinding noise. I thought I stripped out the actuator gears (plastic). Low and behold the output shaft was sliding back into the yoke at the rear end. Coming out of the input shaft side far enough to not engage the front end. Sure glad the splines are tapered, or I would have chewed those shafts up pretty good. The funny part about that is when I took it apart the very first time I noticed the shaft not in the input side. I thought that it was not assembled at the factory right. Well, after complaining to the dealer, they called Arctic Cat. Find out there is a spring added to 2007 models and up that fits inside the yoke so the shaft can not float backwards. That spring number is 1402-026. What makes me mad is that the dealer said there were no recalls or noticies published. I wonder how much they would have charged me for that engineering screw up.

Hope this email helps someone else.

 

well I've been reading and this is what happened to me. other day daughter said 4wd not working on my 04 400 accuator was making noise and seemed to move freely. took a look and saw front drive shaft from transmission turning but not at front differential. found the rubber boot connecting driveshaft had sliped allowing shaft to pull out from front diff. slid it back into place and secured boot with new clamp. problem solved. Just remember its not always the worst problem. start with the BASICS before thinking the worst.

 

Thanks..... I had also put new clamps on boot and tighted them up real good. Mine still slid out from the imput shaft.

 

Yea they should make at least a bulliten. i was thinking worst at first. thanks for the tip on the spring might make one myself.

 

Yea, All you would need is some type of stop that you could slip into the yoke. Some type of stop or bumper would work. Or just order the spring # 1402-026.

I'm glad this information got out there. That's what it's all about, helping each other.