Just put in a new roller cage in front diff on 2008 500ho. When I took the diff apart I thought I would see broken plastic all over the place but nothing the roller cage looked intact.There did not seam to be anything wrong with the old cage put the new aluminum one in and it works great. My question is what goes on the old cage do the clips or spring weaken. Or do the bearings wear down. Thanks just wondering nice to know for the future.

 

The plastic roller cages would either have hairline cracks that would cause them to constantly engage,some would warp which would cause the same thing or just completely shatter like many have found.Rare occasions some have found it was the armature plates fault. Best to change the plate out anyway along with a new aluminum roller cage.

 

believe its cause the plastic cage cant contain the force of the wheels spinning freely and getting a sudden lockup when wheels get traction in some situations thus exploding cage in little pieces I completely rebuilt my popo front gearcase no front drive put the aluminum cage in mine.The plastic one in mine was itact everything else was trashed guess that's when I bought they said 4x4 was not working wonder whyjust having some drive fluid might have helped mine

 

That's just down right nasty looking... I found several just like it...Some diffs I was able to save,some were just too far gone.

 

it was a mess but cleaned up well got to it just in time no water inside but no oil either found front breather line plugged up top don't know if that caused some?

 

There did not look like anything was wrong with my front diff it was full of clean oil no metal bits in the case the magnet worked great but it would not engage. A few times if I got the rpm up it would engage. So I am still not sure why it works now. I plowed snow with it today and worked great Thanks Tux

 

Please disregard my last post I did not see OPT post which explains my diff problems. Tux

 

I'm glad I haven't had any snow to plow. It's supposed to get up to 56 degrees Tuesday then cool back down to the 40s again. I love global warming.

 

Thanks for the replies

 

ME TOO lol.