TRY OHMING OUT THE 4WD HUB COIL WITH A OHM METER TO SEE IF YOU HAVE A OPEN LOOP. THEN WITH THE KEY ON ON FWD GEAR AND AWD ON SEE IF YOU ARE GETTING 12 VOLT ON THE TWO WIRES COMEING TO THE COIL. IF 12 VOLTS PROBLEM IN COIL OR OTHER HUB SUFF. LET ME KNOW AND I WILL TRY TO HELP

 

thanks...

I hope to ohm things out today.

 

check your armature plate... if im not mistaken the slightest bend or warp will cause the hub to work improperly

 

I had the same problem with my 96 sportsman 500, make sure the dowels expand and contract nicely, if not buy the aluminium housing. I filed mine down so I could push through the dowels with a little effort. It's been working fine for a long time.

Good Luck

 

Got it Fixed!!!

Thanks to all!

The electronics were fine, mechanically the rollers and hub surface where they ride were a mess.
I cleaned the rollers up with a wire wheel on a griner, and used a dremel tool to clean up the inside of the hub.
Lots of contact cleaner on the bearings and other surfaces. Reassemble, add Mobil 1 ATF and it drives now!!

Many thanks guys!

Polar