When I put mine back together I put the "spacers" on the wrong sides of the hub and my 4wheel drive didn't work. But the light on the dash came on. Something to check though.

 

Which spacers are you referring too? Are you talking about the output shafts being flipped?

 

Check the switch with a VOM meter. Oops just saw you tried another switch.

 

Did you check the fuse? You can also jump the diff with a wire to see if it's engaging.

 

I have checked the fuse also and the VOM. Now I'm no electrician so not gonna say I did it 100% correct. Which way do you suggest jumping the diff with a wire to see if it is engaging?

 

Maybe someone will chime in. I don't know which wire but can check when I get home. Are you getting any power at all to the switch.

 

The first time I needed AWD it wasn't working. It turned out that the plug was not fully seated in the AWD switch. Plugged it in and then it worked.

My brother had a similar problem. He had accidentally switched the AWD plug with the head light switch. Easy fix though.

 

It shows to be getting power can't remember how much I will check again tonight. I pulled the switch and hooked up the new cheap switch then back to the old one, neither changed anything.

 

I will look at mine when I get home later and see which wire has power to and off the switch.

 

Thanks!

 

After my recall reflash they had to go back and replace my ecu due to 4wd engagement problems similar to what your having.

 

Same thing after my re-flash for recall work my AWD did not work. Dealer had to replace the ECU and install the latest update worked fine after that.

 

Mine won't engage when moving after the ecu replacement. I have to be at a dead stop. Guess it's part of the new software.

 

Update: As of right now I have found out that I have the wrong Sprague from Superatv. Matched it up with the diff number and everything. Apparently there is a short and a long version my diff number calls for the short version however that is not the case. I have a 1/4" To 5/16" Gap between the Sprague and the armature plate so it will not lock in. Superatv is supposed to have the correct one in ten days or so. So we will see if that is the fix.

 

I don't think that will keep the 4 wheel drive light from coming on. You might want to try reseating the big connector on the back of the speedometer. I have seen that cause this problem. It still won't work if you can't get that to light up. With the unit on the bench and all put back together put 12 volts on it. Turn the input shaft, both outputs should turn. If not something is wrong with the diff. It it works on bench and not in RZR you have a wiring problem.

 

So with out the diff installed the light should still come on, on the cluster or no?

 

Key on or runnning in gear makes no difference. The grey and orange are hot. When you hit the switch the 4wd light comes on and kills power to the grey wire.

 

Is the switch bad if it doesn't kill power to the Grey wire?

 

I have a similar problem with my rzr. The 4wd works in H and L, but not in R. The 4wd light on the cluster doesn't turn on in any gear, but the rocker switch is lit. I'm still trying to fully diagnose it.

I unplugged & replugged the front diff plug but to no avail. I need to check voltages and resistances when I get home.

Anyone have any suggestions?

 

Alright guys so I got a 2015 rzr 900. 4x4 isn’t working. Both shafts turn, have power at the switch on Grey Wire and orange wire until you flip the switch then power is killed to the grey one. I have power on one wire at the plug for the harness side and no power on the other with the switch off. It doesn’t change at the plug when you turn the switch on snd the light in the cluster doesn’t come on. The diff is literally brand new.

 

 

My headlights and 4x4 were not engaging, apparently I switched the connections after installing the dash, I switched them around and now the both work. Just a thought.

 

I figured it out. Brand new diff the wires were broke in the heat shrink. Imagine that.

 

op: are your headlights working? the 4wd switch and the headlights share the same ground. i had a cut brown gnd wire in the harness. when i fixed that, both started working again.

 

maybe someoone here can help me, brand new bombproof diff in my 2020 turbo s4, also has hess override switch. switch to 4wd and it doesnt change on the cluster. obvisouly not working. i checked all connects all good. i have 4 volts to that plug which seems wrong (4volts to the battery bar under the hood as wells which is where it gets its power) and ohmed the plug and had 0 resistance. any tips on where to look would be highly appreciated!!! thanks!

 

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