I have read all the posts on this and my problem seems to be different...From what I have read 4x4 switch problems are very common and are easy to see because wheh a problem occurs the 4x4 light will stay on regardless of what position the switch is in

the other day I stopped on a log with all the tires in the air. I had read all about 4x4 problems so I decided to check mine. When I turn the switch off the 4x4 indicater turns off as it should...but the front wheels were still engaged. I F%$#ED with it for a long time, reverse etc, always the same. The light goes on and off with the switch but the front wheels were alwys on.

I don't think any fluid has been changed except for oil but I did damage one of the hub/strut housings when my CV joint broke and the driveshaft popped out grinding on the hub housing.

I have not had time to put it on jack stands - what do you guys think?

 

Anyone?

 

Thedon, If you have all tires up in the air then it would be normal for the fronts to continue to spin. With the Polaris AWD system if it senses that the rear wheels are spinning,(as they would be up in the air) then the fronts will continue to lock in and pull until the rears regain traction even though you have turned off the AWD switch. The fronts won't unlock until the tires are on the ground and the rears have enough traction so that they are overrunning the speed of the front tires so that they will unlock. All the light is telling you is that the electrical power to the front is off. The actual "unlocking" is done mechanically and not electrically. Hope this helps. Sounds as if your system is working correctly.

 

I have to agree that things are all right. I believe the 4x4 in the front dif works with a magnet that energizes with the switch. This magnet engages rollers in the diff so that if the rear wheels travel faster than the front, the front drive shaft, which is always turning from the trans, engages the front wheels. There is a type of "turn buckel" effect that because there was no force against your front tires, the steel rolers were still engaging. I had one of the first 2002 700 twins, which was the first sportsman to use the new front diff. I blew it apart with about 100 miles in 2002 and had to rebuild it. Not cheap.

 

Trailbound, Polaris has beefed up that front diff. since then haven't they? I can't remember what year, but I know I haven't heard about many problems with it the past few years now. I got the black/silver 700EFI. Sharp machines!!!

 

Polaris has redesigned the Armature plate and Roller cage in the Hilliard front diff. I hear the new plate and cage will work in older models.

 

Thanks for the replys - That is what I was hoping to hear!
It was pretty funny though...Let me just make sure my AWD switch doesn't have a problem...HOLY CRAP!

Don

 

I dont know what you guys are talking but on mine if I have 4by4 turned off the back wheels can spin till the cows come home and the front WILL NOT ENGAGE ....AT ALL ....EVER. Now If I switched it to 4by then they will engage right away. I have heard this is a comon problem with the 04.5's and newer since they changed the front drive line set up. If it worked the way You are saying Fire then there would be no need for a four wheel switch at all and You could never do donuts or power slides like I love to do all the time!

 

The front wheels should not engage when in two wheel drive, sometimes the armature plate becomes magnetized and causes this to happen. Try changing the oil first and use the hub drive fluid, this might fix it, if not it's probably the armature plate.

 

When I blew up my 02 front diff, I replaced the cage and armature plate with the new updated ones. Since then no problems with the 4x4 engaging while the switch is in 2x4. I was doing a doghnut while in 2x4 when the front diff engaged. The front tires went from 0-45mph in a spit second. Thats when things went wrong. This new set up has be flawless in my 02 since the rebuild and my 04.5 and 06 have yet to have trouble.