Could be because of the changes in the gear case over time. One spacer is supposed to be removed. That may be the difference on cases mating?

 

After I sent that to keep you updated, I went online to Partzilla and saw the same thing. I'll try again later when I get home from work.

 

on the new coil/cover the pump stick up to high from the housing that the bearing doesn't seat in it and the splined part where the axle goes in doesn't seat in the seal.

I removed the spacer and assembled it with the old coil/cover and as I was tightening it down I couldn't even spin the pinion hear by hand...

 

Sounds like you need to disassemble and recheck your work. Plus did you loosen the back lash screw on the old and new cover? If the cover is removed or replaced the screw has to be heated up to break the locktite and turned out 4 turns. This may be part of the binding. The back lash screw then is adjusted to where it barely touches and then turned out 1/4 turn.Pinion shaft is then turned to make sure the ring gear turns smoothly.

 

Did this issue ever get resolved??? I have the exact same issue with my 09 Sportsman 800 with only 1500 miles there is little to no wear on anything in the front diff.

I have done all the same things already except get a new cover plate.

My 4WD worked flawlessly before I disassembled it to put a Super ATV Sprague Cage and Armature plate in. I have since had the diff out many times to check, everything, and everything is functioning as it should until you have weight on the front tires. I have had it apart with two other competent mechanics and we all agree its assembled properly......I took it for the last test run and had no 4wd, forward or reverse but it would pull randomly left side in reverse with override button pushed.

The front ground is a pulsing ground, but from what I have been told it is sup post to be.

Also my diff did not have that spacer in it that the IPB calls to remove, so it must have been removed prior or never installed. It has a 12/08 build date.

Need some help.....Thanks in advance!!

 

Have you jumped the brown/white to the solid brown in the speedo connector? This may solve the problem. Never heard of a pulsing ground wire effect unless it was caused by the diode in the speedo that transferred the ground path to the front diff.Hence the main purpose of jumping the diff ground wire to a solid ground before it entered the speedo.

 

I have manually grounded the brown and white wire to the Diff to both the frame and the brown wire on the back of the second speedo plug. Also the reason Why the ground was pulsing was because it was unplugged from the differential, once its plugged in it completes the loop...duh....

So I know its not the ground, I am in the process of putting it all back together, I had to do other maintenance while it was apart. I did get the front end together enough to check the 4wd and its not working....... but when I have the switch to the ADC 4x4 it still has no 4wd but I can feel the ADC working!

I am now thinking its the Sprague cage, so I am going on a ride this weekend, then will put the old plastic cage back in and see how it goes.......

 

Unplugged ground could cause a pulsing effect I suppose When you take the Sprague cage out compare it in height,circumference,and slots to the plastic one. Also look at the plastic roll cage closely for any small cracks that you may have over looked. They can function this way,but crack further later on and explode as many have done.Sounds like the aluminum cage may be the problem as you suspect if everything else is correct.Could have been a machining flaw as no one has posted about any problems with them as far as I know.

 

Just got off the phone with Superatv, man they are on the ball with customer service! I spoke to the lead tech, and they are sending a new Loaded Sprague Cage to try and see if that's the issue. He said sometimes the spring tension on the rollers can cause issues if they are too tight.

 

Sounds like a good company to deal with..