Rubber grommet? There wasn't a rubber grommet anywhere on the old switch or the new one. I was careful to seat the switch into the small hole in the shift ball, but it was metal on metal. That's how the old one came out. Just checked the bag the new switch came in, no rubber grommet. Maybe I should come up with a small "top hat" for the switch end?

 

The square rubber block built in at the the tail end of the switch! It fits in a groove in the shift box.http://www.ebay.com/itm/Polaris-New-OEM-ATV-Gear-Selector-Switch-Sportsman-Worker-Xplorer-335-500-/190948232232?pt=Motors_ATV_Parts_Accessories&hash=item2c7566cc28&vxp=mtr

 

Sorry, I thought you were suggesting a grommet at the switch tip. I bought a new switch and the square "housing" fit into the grove tight with no play whatsoever. I did find some very small rubber screw covers that will slide over the switch tip. My guess is that's where the play is and the additional rubber over the tip will eliminate the slop in there. It takes very little pressure on the gear shift to light up the AWD switch. Will let you know the outcome. Thanks again for your help.

 

Put everything back together. Just an "ever-so-slight" pull from a bungee keeps the switch on and still lets me put it in reverse. Tested the AWD on uphill wet pavement and darn near threw me off, so the hubs are working great. Will probably leave it like that for a while. I did find a used gear shift box on ebay for $49. I'll play scavenger and see if I can come up with a bungee-free solution when it gets here. Once again, thanks for sharing your wisdom!

 

Glad you got it working better,but I'd stay away from used shift box parts especially the lever. Rest of the major parts are still available online such as springs,slides,pins,etc that may help stiffen up the shifting and may eliminate the need for the bungee cord to maintain awd.