Polaris Ranger lost front wheel drive

[TeamGeek6]

2004 Ranger was jumping into 4WD when rear wheel slipped (without pusing the button 4WD from the dash) and now the chain to the front shaft seems to have been broken. Havent taken it apart yet.

Anyone know about problems with these "silent chains" or the 4WD selector?

[TravEX]

Man, where have you been! Haven't seen ya on in a while!

Sorry, I can't help ya with your problem. Could the switch have been bad, and the switch stayed open?

Good to see ya back.

[TeamGeek6]

Moved to WA State. Busy with other things. Got a race car down South Im doing some tuning on.

The ol Ranger has been factory equipped with an Explode-O-Matic transmission. Ugly signt inside.

Some schmuck at Polaris didnt bother to put a shear key in the drivetrain, so a front end jumping in and out of gear destroyed a gear in the transfer case, then the chain exploded, then two gears in the transmission got broken from debris. Handful of metal pieces came out.

The #85 (#85 on the parts fiche) gear to the front driveshaft wasnt manufactured properly and came apart. Rough edges on the gear, one of them cracked, then BOOM.

$1400 transmission right down the crapper.

We still dont know whats wrong in the front differential, I suspect a solenoid sticking. it comes apart tomorrow.

Piss poor design to not have a shear key somewhere in that transfer case. They cost 59 CENTS!

Way to go Polaris.:crazy:

I beat the living hell out of the 250R, jamming the shift lever with steel shank racing boots without a clutch in races, and not a mark inside the trans. THATS quality machinery!

Polaris, get a clue.

[TeamGeek6]

More on the Polaris transmission nightmare.

Crappy electrical work appears to be the cause.

The wiring on the AWD switch and solenoid connector are poor quality. The switch termials are incorrectly sized and poorly crimped.
The solenoid connector, and most of the other connectors under the 'hood' are not sealed - cheap.

So, some dummy stuffed grease into them so the grease can foul the contacts and hold dirt.

Measured DC voltage on the solenoid, the voltage hangs up when the AWD switch is thrown Off or On. Couldnt read continuity through the Brown wire from AWD switch and solenoid.

If a wire is breaking contact, that would slam the front differential in and out of gear and hammer away at the transmission.

[MTS]

Tho's Run the Centralized Hillard or the outer ones? the voltage will hang up, it the amature plates are Worn excessivly, or the coil gaps are way out,,

[TeamGeek6]

Naw, I said the wiring is junk. When the crimps are improper and a wire has no continuity, then it doesnt have anything to do with armatures.

[3Razors]

The Poo poos are always the worst in durability..Always broken for one reason or another.