Ultimate Front Diff Thread - Page 2 - Polaris RZR Forum - RZR Forums.net
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post #16 of 607 Old March 26th, 2009, 07:41 PM
 
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Re: Ultimate Front Diff Thread

I still cannot get my awd to engage. how can i tell if its a front diff issue? i have full fluid in it, no noises at all. It seems to be receiving power. I just dont know where to turn.
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post #17 of 607 Old March 29th, 2009, 06:12 PM Thread Starter
 
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Re: Ultimate Front Diff Thread

What do you mean when you say that it "seems" to be getting power.

First, check to see that the front diff is getting power. Use a multimeter to check leads from the engine. If its getting more that 8 volts, then you need to move to the diff. If its less than 8 volts, its something with the switch, computer or wiring.

If you have at least 8 volts, then you need to check the ohms on the diff pigtail. I am sorry that I can't remember what the range is exactly, but I think that its 22-27 ohms. SOMEONE CORRECT ME IF I AM WRONG. If you've got the ohms an issue inside the differential. It could be the armature plate or the cage. You'll have to open it up and have a look. If you don't have the ohms, it should be the coil inside the armature plate.
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post #18 of 607 Old March 31st, 2009, 09:35 PM Thread Starter
 
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Re: Ultimate Front Diff Thread

Well, Dragon Fire Racing came through for me. They got me a new cage and seemed to have fixed the issues. I put all new springs in the new cage and reused the old bearings.

Worked flawlessly. I was nice for a bit, then beat on it just for fun.
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post #19 of 607 Old April 2nd, 2009, 08:40 PM
 
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Re: Ultimate Front Diff Thread

Need some advise.. Out riding this weekend and noticed that the 4x4 was not kicking in. Light comes on with the switch and on the speedo showing 4x4. When riding it will engage when it feels like it, even if it's still switched to 2WD. I don't have any clunking noise or any noise for that matter that is unusual. I have had the RZR for 18 months riding it pretty hard, mostly on the dunes. I noticed that some post were talking about using the wrong drive fluid. I did just change fluid before this ride, but I beleive I used the Polaris LT fluid that is recommended.

My first thought was that it was electrical but put the volt meter on both sides of the switch and its all good.

If it is the cage, how long does the rebuild take if doing it myself?

Thanks
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post #20 of 607 Old April 3rd, 2009, 08:58 PM
 
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Re: Ultimate Front Diff Thread

Cheeto

did you order springs from polaris or find some aftermarket?
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post #21 of 607 Old April 6th, 2009, 08:19 PM Thread Starter
 
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Re: Ultimate Front Diff Thread

Sorry, been gone a while.

I ordered an new plastic cage that came with springs. I took the springs from OE plastic cage and installed them on the NEW DFR cage. Oh, DFR did come through for me. Took them a bit, but they did come through.

sandwarrior, that is exactly what mine did. At the very least, you need to open the diff. I believe that you'll find your cage is shot. Even if the cage is still in tact, it could be that the springs are worn out. Keep in mind that this will ultimately cause the cage to eat itself up. Hope this helps.
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post #22 of 607 Old April 7th, 2009, 08:35 PM
 
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Re: Ultimate Front Diff Thread

Sounds great, I will pull it apart shortly..should be interesting to see what you guys have been talking about.


Quote:
Originally Posted by cheeeto View Post
Sorry, been gone a while.

I ordered an new plastic cage that came with springs. I took the springs from OE plastic cage and installed them on the NEW DFR cage. Oh, DFR did come through for me. Took them a bit, but they did come through.

sandwarrior, that is exactly what mine did. At the very least, you need to open the diff. I believe that you'll find your cage is shot. Even if the cage is still in tact, it could be that the springs are worn out. Keep in mind that this will ultimately cause the cage to eat itself up. Hope this helps.
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post #23 of 607 Old April 14th, 2009, 08:19 PM
 
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Re: Ultimate Front Diff Thread

my rzr will no longer go into 4wd is the a way to disable the awd and make it so you can lock it in or have it out
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post #24 of 607 Old May 5th, 2009, 08:11 PM
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Re: Ultimate Front Diff Thread

I've had problems with my front diff for the past 300 miles, i have 650 total. I've brought it to the shop twice to have it looked at. When I pick it up they tell me that the AWD is working fine. This problem has forced me to get a winch prematurely. I've had to use it more than I'd like to due to the front end not engaging.

According to the Service Manual your supposed to have a minimum of 11vdc at the connector coming from the wiring harness. For some reason my voltage fluctuates from 7 to 12vdc. I think it may be a bad ground, not sure. I have not pulled the wiring harness apart to check,... yet. I Ohm'd the diff and it comes in at 23, which is good. The manual says that it should be 21.6 - 24.4 Ohms.

I check voltage going to the switch at the connector. I have 12vdc at the connector. I jumped the hot to the gray diff power wire, simulating the switch. I check the connector going to the diff and voltage fluctuates. I checked continuity of the switch and its good.

I cut the connector both sides going to the diff, thinking it was the connector. Continuity was good. I soldered in a new Painless 2 wire connector to replace the one I just cut, ugh!

I decided to run 12vdc straight to the diff from the battery, viola! I could hear the coil energize. I had the 08 RZR on jack stands. I thought the front diff would engage. I ran it and it did not. I called DFR and questioned if I needed a billet cage. I explained what I found. They said my voltage should not fluctuate. They also told me that the FWD needs to be under load for it to engage. I put it all back together and will test it Thursday. This really sucks! The service manual does not have a wiring diagram to trace.
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post #25 of 607 Old May 6th, 2009, 07:07 PM
 
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Re: Ultimate Front Diff Thread

Quote:
Originally Posted by sf-RZR View Post
For some reason my voltage fluctuates from 7 to 12vdc. I think it may be a bad ground, not sure. I have not pulled the wiring harness apart to check,... yet.
......
I decided to run 12vdc straight to the diff from the battery, viola! I could hear the coil energize. I had the 08 RZR on jack stands. I thought the front diff would engage. I ran it and it did not. I called DFR and questioned if I needed a billet cage. I explained what I found. They said my voltage should not fluctuate. They also told me that the FWD needs to be under load for it to engage. I put it all back together and will test it Thursday. This really sucks! The service manual does not have a wiring diagram to trace.
Under a load? If the rear wheels are turning, there should be your load.
Doubt a ground problem there, that side just supplies the voltage the ground is made on the other side (when the criteria is met) to complete the engagement!
So at the moment, you've bypassed the switch and have jumped the coil straight from the battery?
Hmm, but the switch is good (with a solid 12v), the connector good (youíve replaced it).......so your thinking if the jumper works then it must be the wire itself?
Here you go take a look, hope it helps.....found on PRC.......http://www.atvgraphics.org/Polaris/R...ingDiagram.pdf
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post #26 of 607 Old May 7th, 2009, 10:53 PM
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Re: Ultimate Front Diff Thread

stumpduster, thanks for the diagram. I'll be tracing it this weekend. I took the RZR out today, with no front diff. The AWD light was on, but no one was home. thanks again.
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post #27 of 607 Old May 9th, 2009, 06:12 PM
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Re: Ultimate Front Diff Thread

I traced wires out today. checked continuity and Ohms. starting with gray wire from switch connector to diff plug, continuity good, Ohm'd 0. next, brn/wht from diff connector to speedo connector, continuity good, Ohm'd 0. next brn from speedo to neutral on batt, continuity good, Ohm'd 0. This leads me to believe that something in my speedo is bad, causing fluctuating voltage. oh yeah, I checked the switch again, continuity good, ohm'd at 0.1.
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post #28 of 607 Old May 9th, 2009, 06:49 PM
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Re: Ultimate Front Diff Thread

can u get it to work with jumpers from batt?

link for crow dog's site!!! www.utvguide.net


running makin trax afco shocks and springs
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post #29 of 607 Old May 9th, 2009, 07:52 PM
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Re: Ultimate Front Diff Thread

Yes, I ran 12vdc separate neutral and posi from the batt and I could hear the solenoid energize.
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post #30 of 607 Old May 12th, 2009, 07:04 PM
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Re: Ultimate Front Diff Thread

I did some more testing. I ran a jumper from the brn to the brn/wht on the connector going to the speedo and the diff energized when I flipped the switch. This leads me to believe that the speedo has a bad circuit. The speedo (RPMs) control when the front diff can be engaged. According to the SM it will not engage unless it is under 3100RPMs. I'll need to test it with another speedo (my brothers RZR) to be sure.
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