I've got this 00 Kodiak that will instantly blow the awd fuse as soon as I turn the 4x4 on, I figured I'd see if anyone might have run into this before I start digging into it.
Thanks,
Roger

 

Id try to find all the connectors, from the switch to the unit in front, and pull them apart and look for water, or corrosion. If things look fine, get some dielectic grease and fill the connectors with it and snap them back together.

If you disconnect the connector at the front diff...then switch into 4wd...does the fuse still blow?
If its Still blowing fuses, after this, then you have to find the pinched wire.