Service Manual

8.14
FINAL DRIVE
AWD Diagnosis
Symptom: AWD Will Not Engage
1. Check the gearcase AWD coil resistance. Measure
between the Grey (C) and Brown/White (B) wires. The
resistance value should be within specification.
2. Turn on the ignition switch and AWD switch and place gear
selector in High or Low gear. Check for minimum battery
voltage at the chassis-side of the AWD/ADC connector.
Measure between the Gray (C) and Brown/White (C)
chassis wires that power the AWD coil. A minimum of 11
Vdc should be present.
3. If electrical tests are within specification, remove the front
gearcase (see “Gearcase Removal”) and inspect the internal
components.
4. 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 5. A wear band with an interrupted wear
mark may indicate a warped plate, which may cause
intermittent operation.
5. Check to make sure the AWD 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. 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 found, replace the cover
plate assembly.
6. Inspect the rollers for nicks and scratches. The rollers must
slide freely within the roll cage and H-springs.
7. Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
Front Gearcase Coil Resistance:
AWD (Pin B to Pin C): 24 Ω
ADC (Pin A to Pin D: 12 Ω
Armature Plate
Check for Wear Bands
Gearcase Cover Plate Asm.
Coil
U-shaped insert
Cutaway View
Rollers
Roll Cage
Assembly