no 4 wheel drive.........

[geonc]

'05 Sportsman....all was good yesterday as the on demnand was working fine...... dropped down into our local water/mudd hole and just the rears were digging me down-----checked to see if switch was in 4 wheel...YUP!

So I'm thinnin' WTF :noidea: flip the switch and the icon is showing on the speedo....tried reverse, no different so I winched out and headed to the garage, checked for voltage ---have it all the way to where the wires end at the diff....jacked it up with all 4 wheels off the ground and started it up....

rears spin and so is the front driveshaft but NO FRONT engaging .......

Now I will admit that the front has had a mind of it's own lately....not allways disengaging when the switch is off and I understand this may indicate a cracked cage---a project I have done on other POPO's--- but correct me if wrong but if the cage did finally shell itself and was bound up in the coil field.....wouldn't it stay locked in?????????

That is the design of the Hilliard clutch....


lil help guys! :hail:

[OnlyPolaris]

i would say busted cage.

[Rubberdown]

I wouldnt say busted just yet, when mine busted, it kinda locked in only 1 side and rode hard to that side. I'd say to drain the fluid, and see what the fluid looks like. Then flush it out with some clean fluid and then re-fill it the exact amount required (5oz if I'm not mistaken) and try it again.

[geonc]

I'll try the flush and fill....the current fluid has only been in about 3 weeks and the old fluid was about as green as the new with no signs of contamination.

Damn I don't need a front diff rebuild at Christmas time:mad2:

Any truth to the rumor of Polaris up-grading the cage from the phelonic to alloy ? Wonder how it will hold up in cold temps...{if true}

[geonc]

OK...drained and flushed ---clean and clear......re-filled with new and still no worky .....

Jacked it up and the front tires spin just as free as can be with no grabbing, noise etc... start up and put in gear and switch into AWD....nutin'......

I ohmed out the wires going down to the diff...no resistance ????? and yet when I check continuity....it shows---- WTF?

Has anyone ever had the coil fry without damaging the wiring harness....I can't find any type of fuse protection....POPO seems to perfer to use 2 self-re setting circut breakers ..............

Or possibly the tab washer that engages with the cage....the one under the snap ring and thrust washer????

I don't have much hair left to pull out guys LOL...... so I guess nobody has heard about the alloy cages?

[Rebel64]

By alloy do you mean the billet aluminum?
If so, I know of at least one person on HL that has that on his Popo.

[Rubberdown]

I know its a long shot, but have your dealer test the ECM for you, my 4x4 was intermitent for a while, turned out to be one of many possible problems with a shity ECM. He actually had to take 3 ECM's out of brand new machines still in the crate before he found a good one that hooked up to his little dohinky tool and gave it a good reading with no problems on it at all.

[Rubberdown]

By alloy do you mean the billet aluminum?
If so, I know of at least one person on HL that has that on his Popo.

How is it working for him? I may try to get one made and tested by someone in need....

[Bigdog800EFI]

My 800 on Nitrous would be a good test platform.

[Rubberdown]

I'm sure it would Vern LOL. Its probably a long ways away since I can barely keep up with the RZR lift kits now, but hopefully after the holiday rush I can get to work on the BF lift and the "other" project you saw pictures of ;) ;) and then maybe then the billet cage.... man I'm getting tired LOL

[Rebel64]

How is it working for him? I may try to get one made and tested by someone in need....

I'll try to find him and inquire about it.

[harmonsbrute]

big dog u got a 800 on nos.... any pics

[geonc]

Rebel,

not sure if actually pure aluminum billet or an mag/alloy mix....I just recall hearing about it but.....damn CRS....can't remember who or where.


Rubber,
the ECM was replaced last year on the recall.....what would the ECM have to do with showing current all the way to the diff ?....and the 4x4 icon showing on the display when switched?

On board diagnostics show no fault....for what that is worth, especially if it is accurate as the fuel level sensor LOL!

cheers for the replys guys ....keep thinkin'!

[geonc]

How is it working for him? I may try to get one made and tested by someone in need....


....in my best Horshack......

OOHHHHH!....OOOOHHHHHH!.....OOOOOHHHHH!



after all I am in need :fish2:------:angel:

[Rubberdown]

LOL at Horshack, funny thing is probably over half of the guys here have no idea who that is.....ehhhhh, Mr. Carter (in my best Vinny Boborino voice LOL)

As for my guess with the ECM, all I know is I was told it could cause all sorts of different problems if it was faulty, anywhere from the winch not working properly, the 4x4 or all the way to completely dead (like the wife's machine when hers was replaced)

[SCRAMMYTODD]

I would guess you have a broken cage. There is a post on "The other site" If Paul will allow it :) I'll put up a link to it. John Deer Gaters use the same front diff and it is less than $100 compared to over $300 for the same Polaris cage.

So Paul if you'l let me link the "The other site" I'll put it up.

[Rubberdown]

sure, I'm not like the "other" site, I want people to learn all they can and if my site will link to another site to help out one of my members, then go for it. I just wish they had the same mentality....

[SCRAMMYTODD]

http://highlifter.com/forum/john_deere_front_diff_parts_work/m_1942879/tm.htm

My local dealer ordered these parts and they are the same as Polaris parts just a LOT cheaper.

The part numbers are MIA 10666 for the rollers and MIA 10667 for the cage. If you pay more than $100 for both peices your dealer is gouging the hell out of you. It should be less than $75 out the door while the Polaris parts would be around $300.

[Rubberdown]

TODD, you have ordered these part yourself????

Are those John Deere part #'s????

[geonc]

DAY-UM!...I vulcan speechless guys :hail: :hail:

THANK YOU very much for the info and link Scrammy and also to Paul for allowing the link to be posted! :high5::high5:

Regarding the extra length......careful measuring on each end and a touch on a disc/belt sanding machine with a table will be a piece of cake! ----if it's really all that nesecary.........

Now....I hope the local Green Deer place has the parts in stock On Monday so I can have my 4 wheel drive working for our New Years eve ride .....with all the rain we have had this past week, it's gonna be hard to ride past the deep holes we have LOL

[SCRAMMYTODD]

Yes they are Deere parts and there is NO need to file them down. They free float in the housing and there is room to spare.

My dealer is a Deere dealer as well and they ordered them just to check for themselves (the service guy rides too) and they are the EXACT same as the updated Polaris parts but a WHOLE lot cheaper.

[Rubberdown]

Thanks Todd, I think I might go ahead and rebuild that gearcase I have sitting on the shelf here with a smashed cage just so i have a spare. I'll probably order all the JD seals as well and any bearings that might also work in this gearcase. Do you know if the bearings are also the same and any cheaper through JD?

[SCRAMMYTODD]

The entire front diff is the same as far as I know and EVERYTHING is cheaper thru JD. Read that link and I think it says if the bearings and seal are the same. I think it's from a Gater HPX or HSX or something like that.

The diff is made by Hilliard and then disributed to who wants to use them. I think it would be even cheaper to get parts directly from Hilliard but I have no idea how to get them.

[SCRAMMYTODD]

Seal kit MIA 10654 and it should be about $15 and I would assume the bearing will be the same as well.

[torkmonster]

That's GOOD info to know!!!!!

[geonc]

That's GOOD info to know!!!!!


YUP! and here's some more.....These prices are directly from my local JD dealer in Smithfield NC... as of 12/31/07

MIA10667 cage kit...complete w/ rollers and contacts -$66

MIA10654 seal kit {listed as "repair kit"] ...both axle sleeve seals ,pinion seal and both square seal rings - $12.25

guess my front diff will be painted JD green :) :whoo:LOL

Better tell those JD dealers to stock up!

Thanks and cheers for the info guys.....