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I have a 2004 Sportsman 400 with the 4wd not working, although it says it’s on on the speedometer cluster. I bought it that way a couple years ago from a guy who said his dog tore at the wires by the cluster years back, he replaced the harness but it still didn’t work and never got around to actually fixing it. I haven’t needed 4wd until now as I am looking to put a plow on this thing. I took apart the speedometer and everything looks and works ok there and even took off the front panel to look at wires under that and I followed all the wires and everything looks ok. I am finding no fuses anywhere.....it’s got pretty low hours and miles (1300) on it for being an 04....anything I should check that I haven’t described above? Maybe the previous guy hooked something up wrong?
 

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How do you know it's not working?

First thing is always change the hub strut fluid. Assuming it's not a 2004.5 and you don't have the centralized Hillard.
 

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I jacked all 4 wheels off the ground and I get no movement from the front when I switch the 4wd on. I have not changed the front gear case fluid so that will be my next step as soon as I can find the fill hole on it!
 

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if its an actual 2004 and not a 2004.5 you have to change or add hubstrut oil. the 2004 and older models had the front wheels locked at the hub. the 2004.5 and newer lock the fronts in the front diff.
 
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