7.14
FINAL DRIVE
Front Gearcase Diagnosis
• Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the gearcase
coil resistance, use the coil harness (Grey & Brown/
White).
NOTE: To test the gearcase coil resistance, use the
AWD coil harness. The gearcase coil should
measure between 22.8 ohms and 25.2 ohms.
2. Check the minimum battery voltage at the Grey & Brown/
White wires that feed the hub coil wires. There should be
a minimum of 11.80-12.0 Volts
present for proper
operation.
3. Inspect the armature plate for a consistent wear pattern.
There should be two distinct wear bands (one band inside
the other). If only one band of wear is present (or if there
is wear between the two bands, inspect the coil area as
indicated in Step 4. A band with an interrupted wear mark
may indicate a warped plate, which may cause intermittent
operation.
4. Check to make sure the coil is seated in the U-shaped insert
that is pressed into the gearcase cover. The top of the coil
should be seated below the U-shaped insert. The U-shaped
insert controls the pole gap. If the top of the coil is above
the surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to engage the
AWD system. If this is the cause order a new Cover Plate
Assembly.
Front Gearcase Coil Resistance:
24  ±10%
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
Armature Plate
Check for Wear Bands
U-Shaped Insert
Coil
Cutaway View of Gearcase Cover
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