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Discussion Starter #1
Hi, so i bought a used 06 foreman 800, seemed ok when i bought it, i noticed a difference when i engaged the 4x4 when i was riding around. Well now that there is snow i noticed that i don't have much torque coming from the front wheel in forward and reverse with awd engaged. Back wheels spin a whole lot and the front wheels don't want to dig me out at all as if they are not engaging. Sooo I read the forums and decided to tear the front diff apart, thinking it could be the cage or the armature plate.
When I pulled it apart the cage was fine, the rollers seem a little worn but nothing to crazy, the plate seemed a little worn so i replaced it just in case. put it back together and still nothing. tested voltage and was getting 12 volts to the diff. I don't know what else to do next. could it be the rollers? its just not grabbing on to the axles... Any help is appreciated.
 

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Discussion Starter #3
Yes tried jacking it up and 4 wheels spin but if I stick my foot on the front tire putting resistance on it it can't overcome it. Especially the right front tire
 

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Have you checked the resistance of the coil? Try unplugging the coil and connecting 12 vdc on the coil from a separate source
 

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Discussion Starter #5
I checked that the armature plate was magnetising when I had apart but never checked the resistance. I stripped the wires and touched it to the batteries and the plate stuck to the coil. How would I check the resistance of the coil and whould I have to replace the side cover if the coil is bad?
 

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Unplug the coil wires, use an ohm meter and connect the meter to the leads going to the coil, but since you checked that the plate stuck to the coil, I think that was sufficient
 

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Discussion Starter #7
Yah I'm stumped here, my brother grizzly and says my sportsman is just weak... I still think there is something wrong with.
 

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Discussion Starter #8
Do you think the big drive gear that holds the cage maybe the cage compartment on that is worn? The quad only has 1500 om on it
 

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If the rollers where showing wear them and the H springs need replaced. Also, the cage can be cracked without being easily visible. You have to get it really clean with all the rollers and springs out and twist/flex it to see the crack. That may be why the rollers are showing wear. The H springs also lose tension. The armature plate must be PERFECTLY flat and undamaged along with the shim. Finally, did you move the set screw and thrust button? If so, it has to adjusted just right to maintain proper lash of the ring gear. need to also make sure the bearings have no lateral play.
In a nut shell, everything has to be just right for it to function properly or you'll get intermittent or less than full engagement like you have.
For your machine, you can get the cage, rollers, springs, armature plate, shim and all for around $130 IIRC from John Deere dealer Green Parts online. The JD Gator uses the same front housing. Search the forum and there's a couple discussions listing part numbers etc. I'll look if I get time.
 

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Here's the link:
https://www.greenfarmparts.com/Default.asp

Here's full list of ALL part numbers including bearings and JD numbers at the bottom:
Front Diff:
2 Federal Mogul 710308 (output seals)
2 Federal Mogul 6008. C3 (OUT PUT BEARING)
1 Federal Mogul 9748 (input seal)
1 Federal Mogul 6306. C3 (input bearing)
Seal kit MIA10654
A-plate MIA10656
roller kit MIA10666
cage kit MIA10667

Here's a link to the forum thread discussion:
http://www.polarisatvforums.com/forums/polaris-sportsman/4896-john-deer-front-diff-parts-fit-sportsman.html
 

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Discussion Starter #12
Hey thanks for all that info. It's great.
So when I pulled the cage out, all the rollers fell out, I noticed the clips had lots of spring still. I don't know if that's normal.

The armature plate is new and I checked on a tile that it was flat.
I checked the cage and it still looked great. But there might be a crack I missed.
I did take out the adjusteing screw, when I out it back in I went all the way tight and then backed it off half a turn. I am not 100% that is correct
 

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Sorry, I forgot about this thread. Lay it down on its side. Back the screw out 3-4 turns. Put Loctite on the threads then tighten down to lightly seated then back out 1/4 turn. Set the case up and spin it at least 4 turns (a full revolution of the ring gear). If a tight spot is felt back the screw out another 1/8 turn. Repeat the last step until you get an entire revolution with no tight spot...smooth. It take 4 turns of the shaft for one full revolution of the ring gear.
 
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