I`m pretty sure I have read every post on the subject and I think I found another problem that hasn`t been asked. Today I took the right side apart to replace both seals because 1 was leaking and I figured since i was in there i`d do both. Heres my problem I tightened the castle nut to 12ft lbs spun the rear wheels about 3 full revolutions in both directions lostened the nut and retightened it to 10.5ft lbs cap on filled with demand drive fluid waited 10 minutes turned hub to the 3 O;clock position drained excessive fluid allen nut on. I started quad and no AWD. I then pulled the hub back off and checked to see if the coil was working and it nearly pulled the Armature plate out of my fingers from 1/4 inch away so I know for sure its working good. I did run the quad for about 15miles with no fluid in the hub because of the leaking seal. I took apart the hillard and cleaned everything, the rollers are free moving and nothing seems to be binding.
It to me feels like the spring on the hillard is to tight is it possible that running it without fluid I heated the hub enough to shrink the spring on the hillard????
Tomorrow I`m going to stretch the spring evenly and see what happens if that works I`ll be headed back to the steelership for a new 1.