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4x4 stopped working on my 04 ranger 500.all mechanicals seem to be ok . any ideas ??

Sorry its a Polaris 500 ranger

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Any light's lit 4X4 switch on the instrument cluster ?
Four-Wheel Drive Systems The electronic-shift four-wheel drive system consists of the following components:

  • Transfer case (For transfer case repair procedures, refer to Section 308-07B ).
  • Four wheel drive control module
  • Mode select switch (MSS)
  • Gearmotor encoder assembly
  • Do you know what all is involved in your 4X4 system ?
  • Principles of Operation
    Mechanical Operation
    In the 2WD mode, torque from the engine is transferred through the transmission to the transfer case, which in turn drives the output shaft that drives the rear axle.
    The 2WD to 4WD HIGH shift is accomplished when the 2WD to 4WD HIGH shift fork moves the mode sleeve to engage the drive sprocket to the rear output shaft. The drive sprocket turns the chain which turns the front output shaft driven sprocket on the front output shaft and the front driveshaft.
    The 4WD HIGH to 4WD LOW shift is accomplished when the 4WD HIGH to 4WD LOW shift fork moves the range sleeve to engage the planet carrier to the main shaft. Torque for the input shaft is then transmitted through the sun gear, which then turns the planets. The planets, which are now engaged to the output shaft, provide a gear reduction.
    With the shift selector in NEUTRAL, no power is transmitted to either the front or rear axles. All the planetary gears turn freely with the input shaft, and the chain sprocket floats freely on the output shaft.
    2-Wheel Drive
    When 2WD is selected, the range sleeve at the center of the front planet slides forward, putting the transfer case into the high speed range (direct drive). The input shaft and the rear output shaft are locked together. This results in direct drive, straight through to the rear driveshaft. In addition, the 4-wheel drive mode sleeve is disengaged so none of the 4-wheel drive components turn.
    4-Wheel Drive - 4WD HIGH
    In 4WD HIGH, the range sleeve remains in the same position as it was in 2WD. The action of the shift lever causes the mode sleeve to move rearward, locking the drive sprocket and chain to the rear output shaft. This causes both the front and rear wheels to be driven in the high range.
    4-Wheel Drive - 4WD LOW
    4WD LOW allows for maximum pulling capacity. Shifting into 4WD LOW causes the range sleeve to move rearward and engage the planetary gear to achieve gear reduction. The result is that the output shaft now turns more slowly than the input shaft. This action increases the pulling capacity available to the wheels.

Posted on Dec 15, 2016

  • Jeff Armer Dec 15, 2016

    Or do you have Four-Wheel Drive Systems — Electronic Shift ?
    Transfer Case — Electronic Shift

    The four-wheel drive electronic shift-on-the-fly feature electrically shifts the vehicle transfer case between 2WD, 4WD HIGH, and 4WD LOW. The system mode is selected by the operator through the mode select switch (MSS) on the instrument panel. The operator is informed which mode the system is in by two instrument cluster indicators: one for 4WD HIGH which appears as 4WD, and one for 4WD LOW, which appears as 4WD LOW. Shifts into 4WD HIGH can be made at any speed. When shifting into 4WD HIGH with the vehicle stationary, tooth blockage may occur preventing shift completion. When the vehicle is driven above 8 km/h (5 mph) the shift will complete. When shifting in or out of 4WD LOW, the four-wheel drive (4WD) control module requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal be applied, and the transmission be in NEUTRAL (automatic transmission) or the clutch pedal be depressed (manual transmission).

    The gearmotor encoder assembly is mounted externally on the transfer case. It drives a rotary cam which moves the mode fork and range fork within the transfer case between the 4WD HIGH, 4WD LOW, and 2WD range positions.

    The four-wheel drive (4WD) control module controls the gearmotor encoder assembly that shifts between 4WD HIGH, 4WD LOW, and 2WD modes.
    This has no wheel locks !


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Did you turn the locks on the wheels, or check the fuses

Posted on Dec 15, 2016


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