AWD problem with my 2008 Polaris Ranger XP

Avondale · Jul 18, 2011

I am having a problem with my Ranger, seems to be with AWD system. When running in normal or 2WD, without selecting AWD, appears like the left front wheel "engages". Steering becomes difficult. Had some success freeing up when reversed in normal or 2WD and then went forward again but now does not help to solve problem.

Any ideas ?

Thank You for whatever help you can provide.

greasemonkeyok · Jul 18, 2011

Have you traced the wiring from the electric switch to the solenoid? Just a guess.

TOMMYHPX4X4 · Jul 18, 2011

trace back all your electrical connections fromt the switch to the front dif and unplug them and pack them with dieletric grease.sometimes they become packed with dirt or other stuff and lose their connections .i ran into this problem with my rhino not with the 4wheel drive system but the cooling fan and it ended up being just plain old dirt build up.the dielectric grease is a must for any offroad utv or atv i would sugest you take all your connections loose one at a time and pack the grease in them and reconnect them do the spark plug too . if you run across any loose connections you should be able to just squeaze them with some needle nose plyers to get them snug again.

cdaigle430 · Jul 18, 2011

If I'm not mistaken, when you select awd from two wheel drive there is a selanoid that engages the front drive shaft. I don't think it's the front drive shaft or anything electrical.

It looks like the limited slip in the front axle. When was the last time you checked the fluid in the froint axle? When you do, does it look milky? I'm just wondering if the locking mechnism gets stuck inside the axle. Also, I think Polaris uses a magnetic locking system and I've heard this can happen if it becomes magnetized even when in 2wd.

Rustyiron · Jul 18, 2011

Thers a hub that is not disengaging. Check the hub oil. The 4wd works pretty simple, there is a magnet in each hub that "locks" for fwd. Pretty simple but the diag. is the PIA for me. I have one (polaris atv) that does it now and then, and being not bothered enough by it to make me work on it, I have found that when it hangs up, drive over some stump or something that is big enough to let the problem wheel come off the ground and that works every time for me. ( the free wheel on the stump and the locked wheel in the air)slowly!

Avondale · Jul 18, 2011

Thanks for some ideas to start working on. I put machine on axle stands and spun each tire with no problems up front. Both wheels turn freely independant of each other so not locked now.

This machine has a magnetic clutch to enable AWD up front in gear box and not in each wheel hub.

Changing gearbox oil is a real challange on this model made worse since I put the Polaris sold snow plow package on. Heavy duty mount plate covers the drain hole on bottom. Side plug hole is all but impossible to get to, even with inside fenders off (rad hoses and frame member in way). Service manual recommends draining completely then adding correct amount of oil back. Next time I take snow plow plate off, will have a hole installed through mount plate to align with drain plug.

David_Kb7uns · Jul 19, 2011

If it is like my Polaris RZR, there is a cage with rollers inside that engages the front wheels when the rears slip. Sometimes the armature plate gets warped or on some the cage is plastic and it breaks and then things get jammed in there and then things lock up. Get a hold of the service manual and parts breakdown.

David Kb7uns

Avondale · Jul 19, 2011

Thanks. I now have the service manual and down-loaded the parts list. Hard job is actually getting the gear box off and out. Major time and effort for this repair. Hope this is not a common, recurring failure.

I have other machines on my farm, (Kioti, C/IH, White, Arctic Cat {2} Kawasaki, Yamaha, Honda), that do not seem to have the same level of problems as I am currently experiencing with this one.

In my opinion, this is a very capable work horse but POLARIS parts are expensive and they have a thing for "special tools and proprietary material" that I am not keen on. By way of example, Polaris brake pads, Polaris oil & filter products (for gear boxs and engine), etc. The parking brake pads and speedo have already failed on this machine. This could be my last Polaris product if the failures and parts price issues continue at the current rate.

David_Kb7uns · Jul 20, 2011

For more info and theory of operation of the Hilliard FDS-1 go here.

Hilliard Industrial Clutches, Brakes, and Oil Filtration

It got to the point on the RZRs that the plastic cages were breaking that you can get aftermarket ones made of billet aluminum and some of the newer ones are no longer plastic. But it is not easy to get new rollers and springs if they are damaged and you may need to get a whole cage just to get them.

David Kb7uns

Avondale · Jul 20, 2011

Thanks for the info. Currently, AWD is working but I am looking for a better solution than the current OEM kit to be on hand for when it does fail. This site may be the answer I am looking for.