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Discussion Starter #1
I just rebuilt my sprague carrier with the billet one and installed everthing into carrier as told to..i have power at plug,but my awd will not kick in...dealer told me to replace flat armaure and it will fix...any input on how this will fix the issue thanks
 

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Not only check resistance also check the u- shape insert where the coil sets and the armature wear marks as noted in manual. You can also check the awd wiring thu the spedo and to see if its sending power to the coil. I first check spedo then power at plug by diff and then coil resistance and check for short and then tare down and inspect the armature plate and u- shape insert.
 

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Discussion Starter #4
what do you check at speedo. checked all wires and ohmed out plug..got 23.8 ohms.. i know i'm getting power..i just replaced the armature plate...will the front wheels engauge with all wheels in air on jacks if i rev it up in awd or does it need to be on ground..
 

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Discussion Starter #6
could you see issues with the armature or not i just replaced mine tnite but haven't taken off the jacks but my front wheels will not lock up.. maybe need to ride to find out...
 

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dumb question but do you have a gear indicator and 4x4 indicator lit up on insterment cluster?

also some people have had to replace the springs on the carier the old one's didnt work right
 

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Go through the punch list of items that are required for the 4WD to engage...
I believe all of them have been listed here in this thread..
If not, make a list and then go through it..
 

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I am in the exact same situation. I replace the carrier, new h-clips, new armature, new seals. All electrical checked and rechecked it was all ok I then replaced the speedo thinking there was a problem internally, didn't work. I put it up on the lift and ran a direct connection from the battery to the front diff I could hear the armature engage when voltage was put to it. I then ran it up on the lift with the direct connection from the battery and the fronts locked in and started turning. I assume now that somewhere in the system there is a bad ground although I have not been able to find it!?!?! I have traced every wire and followed every popo service manual flowchart. I am completely stumped.

anyone have another idea???
 

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Toggle switch!!! Sorry man ain't got a clue. Just researching so if I ever have a issue I know what to do.
 

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I had the same problems. jumpers mine directly to the switch and ground and it has worked perfectly for the last 500 miles. I never hit the switch when the rear tires have no traction but I use it all the time at any speed.
 

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OK, on same not, i replaced my internals with holz aluminum cage and rollers, new arm plate , new u shaped button checked wiring and when i put it in 4wd it works but if it stresses at all it jumps and pops and makes noise mlike its slipping and still has a broken plastic cage? and no 4wd until its less stressed any ideas? bought to drive it into a tree at 30 and get ins money and a new rzr......
 
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