I am having an issue with my awd.
I have already searched and found this to be common. I learned the hubs are
Magnetic on these machines. I have tried various things before i posted as well.

No AWD light.
Speedometer (needle only) doesn't work.
I tried grounding brown wire under access panel to frame and also to a spare battery. Didn't work.
I just drained the front diff fluid. Dark grey, no metal or anything unusual. Seems to be original fluid. 770 hours.

I also have front end torn down to just the axle shafts because I am doing A arm bushings as well.

Flushed diff. Now going to add new fluid.

Where should I go from here?

 

If you have the 04 model with the awd in the hubs and have already tried to jump the brown/white awd ground wire in the speedo connector and it still doesn't have awd on the display,you might want to try a reground closer to the hubs like in this video.You can loose ground path here also.
IF you have the 05 model with the centralized awd in the diff,a cracked roll cage was a common problem. Item#8. http://www.cyclepartswarehouse.com/f...005&fveh=39672

 

Ok thanks for the reply!
It's the 05 model with centralized AWD in the diff.
The plastic carrier would cause the light not to come on the switch as well?

 

No the roll cage wouldn't cause the non awd light,but again a faulty ground or power wire to the diff could. Just make sure you jumped the correct wire in the speedo harness,the brown/white to the brown or a frame ground.This just bypasses the awd ground path from going through the speedo. Plus check if you have power on the diff hot wire. You can even jump the small diff ground wire to a better ground and see if it works.

 

Here are two pictures.
I hooked a volt meter up to the connection under the hood, im getting nothing from the power wire coming from the awd switch.
I spliced the brown/white wire and tried grounding it to frame, no luck.

 

http://i922.photobucket.com/albums/a...s/IMG_0633.jpg


http://i922.photobucket.com/albums/a...s/IMG_0632.jpg

 

Don't over look the connector and wiring on the gear position switch that ties in with the awd switch also.If you don't have voltage to the awd switch in and out,you'll have to back track to the splice connectors and see if you can find the problem in the wiring. Not an enviable job as it could be a shorted wire or even a connector pin not making good contact stopping the flow of power.