Update and a few questions. Ive got the gearcase out this afternoon, after pulling the half shaft apart then having to try to get the CV boot back on(still couldnt, need the tool), and I wish the manual would have mentioned to remove the fan for enough clearence. I tested OHMs at the coil and it read 25.4. but the magnet didnt seem to have any pull. Will it only have that if it has 12 volts? I found the the armature plate has two wear spots. The outside one is smooth even wear all the way around, no uneven wear spots. The inside groove is spotty. every half inch or so, the paint isnt wore off as much. Im assuming the plate is warped(going to replace). Everything else looks great. Cage is clean, rollers are clean, H clips look good. I pushed each roller in the cage and they pushed back out like i assume they are suppose to. Bearings are in excellent shape, ring gear and pinion are like new. Other than the armature plate, it was VERY clean inside.My dilema is do I replace the rollers and cage with JD parts since I already have it open? If I do decide to go with JD parts, how much of that do I need to replace. I only want to replace the rollers cage and springs so I dont have to do this again unless a bearing goes bad. Can I get away with just replacing the rollers and cage, and springs, or should I find and replace with new bearings and seals and in JD as well. I did find a fairly extensive parts list from JD that fits in numerous polaris models. This is the parts list and what they fit from John Deere

CAGE(1)-MIA10667
ROLLER KIT(1)-MIA10666
SPRING KIT(1)-MIA10665
BEARING(2)OUTPUT BEARINGS/CV SHAFTS-MIA10661
BEARING(1)INPUT BEARING/PINION -MIA10672
THRUST BEARING(1)-MIA10663
PLATE-MIA10656(1)
REPAIR KIT(INCLUDES SEALS AND O-RINGS)

Year Product Model Assembly
2008 RGR RANGER 6X6 700 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RF68AD/AF/AZ
2008 RGR RANGER 4X4 500 EFI DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH50AF/AR/AT
2008 RGR RANGER 4X4 700 EFI/XP ALL OPTIONS DRIVE TRAIN, FRONT GEARCASE (Built 8/28/07 and Before) - R08RH68 ALL OPTIONS
2007 RGR RANGER 500 2X4/4X4 GEARCASE, FRONT - R07RB50AA/RH50AA
2007 RGR RANGER 700 EFI 6X6 GEARCASE, FRONT - R07RF68AD/AF
2007 RGR RANGER 500 EFI 4X4 GEARCASE, FRONT - R07RH50AF/AR/AT
2007 RGR RANGER 4X4 700 EFI/LE GEARCASE, FRONT - R07RH68AD/AG/AH/AK/AL/AO/AP/AW
2006 ATV MAGNUM 330 4X4 HOUSING, FRONT (DEMAND DRIVE) - A06CD32AA/AB/AC
2006 ATV SPORTSMAN 450 HOUSING, FRONT (DEMAND DRIVE) - A06MH46 ALL OPTIONS
2006 ATV SPORTSMAN 500 HO HOUSING, FRONT (DEMAND DRIVE) - A06MH50AA/AB/AD/AF
2006 ATV SPORTSMAN 500 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH50AQ/AX/AY/AZ/AL/AT
2006 ATV SPORTSMAN 500 HO INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FB
2006 ATV SPORTSMAN 500 EFI INTL HOUSING, FRONT (DEMAND DRIVE) - A06MH50FC
2006 ATV SPORTSMAN 700 HOUSING, FRONT (DEMAND DRIVE) - A06MH68AA/AD/AF
2006 ATV SPORTSMAN 700 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH68AQ/AT/AX/AY/AZ
2006 ATV SPORTSMAN 800 EFI HOUSING, FRONT (DEMAND DRIVE) - A06MH76AL/AQ/AT/AX/AY/AZ
2006 RGR RANGER 500 2X4/4X4 HOUSING, FRONT (4X4) - R06RD50AA
2006 RGR RANGER 500 4X4 EFI HOUSING, FRONT - R06RD50AB/AC
2006 RGR RANGER XP 4x4 700 HOUSING, FRONT - R06RD68AA/AB/AC/AD/AE/AF
2006 RGR RANGER 6x6 EFI 700 HOUSING, FRONT - R06RF68AA
2005 ATV MAGNUM 330 4X4 FRONT HOUSING - A05CD32AA/AB/AC
2005 ATV ATP 330 4X4 FRONT HOUSING - A05JD32AA
2005 ATV ATP 330 4X4 QUAD FRONT HOUSING - A05JD32EA
2005 ATV ATP 500 4X4 FRONT HOUSING - A05JD50AA/AB/AC
2005 ATV SPORTSMAN 400 FRONT HOUSING - A05MH42AB/AG/AH
2005 ATV SPORTSMAN 500 HO/INTL FRONT HOUSING - A05MH50AB/AC/AG/AH/AL/AT/FB
2005 ATV SPORTSMAN 600 FRONT HOUSING - A05MH59AK/AN
2005 ATV SPORTSMAN 700 EFI FRONT HOUSING - A05MH68AC/AS/AT/AU/AW
2005 ATV SPORTSMAN 700 FRONT HOUSING - A05MH68AK/AN/AD
2005 ATV SPORTSMAN 800 EFI FRONT HOUSING - A05MH76AC/AT/AU/AW
2005 ATV SPORTSMAN MV7 HOUSING, FRONT - A05MH68AP
2005 RGR RANGER 2X4,4X4,6X6 FRONT HOUSING (4X4)(6X6) - R05RD50AA/AB/AC/AD/RF50AA/AB
2005 RGR RANGER XP HOUSING, FRONT - R05RD68AA/AB

 

The coil wont have any pull until it gets 12 volts. Any pull at all would be from the armature plate being slightly magnetized. You can test the coil with jumper wires to a battery and see if it pulls the armature plate tight. Does sound like the armature plate is the problem as it should have two solid wear rings on the plate.Can cause intermittent or no awd. Have had this happen before. As far as using JD roll cage parts, others that have replaced the roll cage with them can give you better answers than I could,but knowing the trouble with the plastic roll cages in the past and since you have it apart,no way would I reuse the plastic roll cage! OPT

 

Thanks OPT. Just purchased all the parts I need. Some from cheapcycleparts. some from ebay and the rest from a John Deere Parts Store online. I ordered 2 new boots for left axle shaft, as they were weather checked, and didnt want to have to do this in a year, 2 new circlips, clamp for the vent tube(shattered), new roll pin, 2 new lower ball joint boots, roller kit, cage,springs, armature plate, and seal kit, for just under $200.00. I am very pleased with cheapcycleparts. I hope everything works.

 

Well you have given me a little hope as I have the same exact issue as you and I have to tackle this problem ASAP. How much drive fluid did you have to use in the front diff? Only problem I have that you don't is my reverse override isn't overriding lol

 

Manual on yours says 5 ounces hub fluid or fill to the bottom of the fill threads. Try a fluid change first and see if it helps. OPT

 

Hey thanks for the input and ya I'm gonna try a flush first I've read numerous post where that's been all that was needed.

 

Well lets pray the front diff flush works today lol could certainly use some good news!

 

pay close attention to what drains out to see if there is any small parts are in the oil. most likely a roller cage is broke.

 

I thought about doing just the oil change first, but i had a feeling the armature plate was bent. Ive only owned the ATV for about 5 months and didnt use it all that often, but when I did drain it, it was very low. Maybe an ounce came out. That is why I am so suprised nothing else was wrong inside, but other than the plate, everything else was imacculate. Maybe a few nicks in the the rollers, but thats it.

 

Armature plates are what we had the most problems with in the beginning when the centralized awd systems came out. Armature plates warping,not making good contact,intermittent awd. Then as time went on the plastic roll cages started cracking. It's a good thing you're not just replacing the the plate only,but replacing the roll cage with an aluminum one also! They almost all eventually will have problems.There's nothing worse than have to go back in to repair something else a little later on. OPT