My front diff locker won't disengage, its not the cable i had it competely out. My 4x4 engages and disengages as usual. The lever moves. Has anyone else had this prob? What do i need to do? Thanks in advance.

 

Drain oil from the front diff gear box and inspect the oil for any metallic debris. Let me know what you find. The worst case is the seized up spider gears.

 

My Guess would be that you pulled the lever to lock up the front end either while a wheel was spinning or while you were moving, there is a small pin that drops in to lock everything up and if you are moving too fast, mechanics say 'at all' then the wheels don't mesh correctly and the small pin bends and won't release when you release the lever, you may hafta replace this pin, I hope that's not the case but that is what it sounds like to me.

 

Yah Thats what it sounds like N2Q, guess ill have to tear apart that front end. Aren't these machines variable differential control meaning the more you pull the more it engages?

 

I could see 4x4 engaging but not diff lock engaging where on the fly could hurt it. Just thinking out loud.

 

4x4 engaging is electronically controlled, so even if you flip the switch to 4wd it would not engage if the vehicle speed is higher than the programmed upper threshold (11.5 mph). The diff lock engagement is 100% mechanical and you can engage anytime you wish. Can it hurt it though? It all depends on the magnitude of difference in the rotational speed between the LH and RH side wheel. I would suspect the damage would be just burnt up friction plates. Mine still has the original diff lock components after 2 years of hard riding - used diff lock quite often in snow and mud.

 

If the frictions were burnt up wouldnt i have the opposite problem? More than likely the mechanism that engages the frictions is jammed or I blew the spider gears and there jammed. Also, by your logic, if i burn up my rear wet brakes they would always be dragging. I severely doubt this to be the case.

 

I didn't mean to say your friction plates were burnt up and that's causing the problem (diff-lock not disengaging). I just commented to your statement if engaging the diff-lock on the fly would hurt or not. Got side-tracted there.
On my verf first post, I wrote about possible "spider gear seizure". And I suggested to check the front diff gear box oil for any metallic debris as for usaul sign...