Again my 2004.5 500HO AWD will not disengage either in AWD or 2WD. This is after the dealer put the wrong front diff fluid in then rebuilt the hillard. I have put about 11 miles on it before it failed, again.

The dealer said it just needs an adjustment. It is the 2004.5 model with the central hillard not the outboard hubs.

My questions are, is there an adjustment for the hillard?

How many miles can I get out of the hillard before I need another adjustment?

Thanks for any input...

 

Today I'm going to talk to the dealer so he can show me how they are going to adjust the hillard. I'll let you guys know what I find out.

 

Ya there is an adjustment. It's the loose nut mechanic that needs to be adjusted. The haftshaft to his noble-woble is out of round on his square side.

 

I have not had one of these apart yet but as far as I know there is no external adjustment.

It is just a matter of time before I will work on one and when I do I will report the strait story about the problems and the correct fix.

 

I called a couple of other Polaris dealers and they all said there is no adjustment on the hillard. I'm currently on hold with Polaris Industries waiting to talk to a tec. I'll report back when I know something. If anyone else can help me with this question, please don't hesitate to chime in. Thanks.

 

The dealer showed me the external backlash adjustment screw yesterday. He adjusted the backlash, changed the fluid and tested it. He said it works fine now. I'll be picking it up today. I hope this cures the problems. I'll report back when it fails again. Thanks for all the help.

 

OK now exactly where is this screw?

 

I just looked at mine. I see a small allen screw sticking out the right side.

You have to go through a hole in the frame to get to it.

That must be it.

 

That's it the allen screw. Well I just picked up my ATV and drove it around my property. The AWD kicked in several times in 2WD. Also in AWD, it kicked in without rear wheel spin, and my front suspension makes all kinds of sqeaking noise. So far the diff has not bound up. I'm going to be giving the dealer another call. Does anyone have any ideas what I should be asking the dealer?