Front differential won't work

flyalot · 02-07-2010, 10:26 AM

I have a 2007 Brute Force. I went to plow yesterday after the heavy storm. While plowing my way out of the barn, the front wheels quit spinning. When I put it up on jackstands, all 4 wheels turn as they should and the 2 wheel and 4 wheel switch works as it should. If I put it in 2 wheel, the front quit spinning. 4 wheel, you hear the actuator engage, get the indicator, and the front start working. So I know the actuator is working OK. The problem is once it has to pull weight, they won't spin. It's like the clutch pack in the front differential is bad. I drained the oil, and flushed it out 2 times with new stuff, then refilled. Same result. The oil was almost clay colored. I am afraid it is the clutch pack but hoping someone has another idea. This thing only has 40 hours on it and I know I haven't swamped it. Thanks for any advise.

greasemonkey · 02-08-2010, 07:50 AM

Well even if the clutch pack is worn one whell should still spin so if both stop working you have other problems.

05KawBoy700 · 02-08-2010, 11:44 PM

You are going to have to pull the diff out and open it up, did you notice any metal shavings in the oil when you drained it? Like greasmonkey mentioned, the clutch packs in the front diff only engage the locker. You should still have at least one of the front wheels spinning in 4wd.

flyalot · 02-09-2010, 02:50 AM

No, there were no metal shavings. The oil just was really an weird grey color, I've never seen anything like it. Like I said, this thing only has 42 hours on it. Anyhow, I flushed out the differential really good until I got regular colored oil to come out. Now, I take it out and if I put the front wheels on dry ground and the rear on ice, and just put a little pressure on front brake it will just sit there and rear wheels spin spin. If I put all wheels on ice and hit the throttle only the back wheels spin. The only thing different now, if I pull the differential lock in, the left front will grab and go. I know something isn't right but I am stumped. Like I said, up on jackstands, not running, 2 wheel engaged, if you turn either wheel, the other one turns same direction. Put it in 4 wheel, turn one the other one turns oppisite and of course it turns the shaft coming from the tranny. I hate to pull differential but it is looking more and more like that.

flyalot · 02-09-2010, 04:37 PM

OK, figured it out. The right axle pulled out from the differential. The circlip is missing and the end of the shaft is rounded off. Looks like I need a new shaft. I looked on all the websites I could find and I don't see a separate breakdown for just the part that goes into the diff. Found a whole shaft for $115. I just wondered how this happened and want to make sure it doesn't happen again. Any ideas?

05KawBoy700 · 02-09-2010, 10:14 PM

That is pretty wierd, and honestly I'd be suprised if the splines on the inside of the diff are still in good shape. You really shouldn't be having that kind of touble at 42hrs. Glad you seem to have found the problem.

02-07-2010, 10:26 AM	#1
flyalot Junior Member Feedback Score: 0 reviews Join Date: Feb 2010 Location: Beaver, PA Posts: 3 (0)	Front differential won't work I have a 2007 Brute Force. I went to plow yesterday after the heavy storm. While plowing my way out of the barn, the front wheels quit spinning. When I put it up on jackstands, all 4 wheels turn as they should and the 2 wheel and 4 wheel switch works as it should. If I put it in 2 wheel, the front quit spinning. 4 wheel, you hear the actuator engage, get the indicator, and the front start working. So I know the actuator is working OK. The problem is once it has to pull weight, they won't spin. It's like the clutch pack in the front differential is bad. I drained the oil, and flushed it out 2 times with new stuff, then refilled. Same result. The oil was almost clay colored. I am afraid it is the clutch pack but hoping someone has another idea. This thing only has 40 hours on it and I know I haven't swamped it. Thanks for any advise.

02-08-2010, 07:50 AM	#2
greasemonkey Senior Member Feedback Score: 0 reviews Join Date: Apr 2009 Location: Reading,Ma. Posts: 633 (0)	Well even if the clutch pack is worn one whell should still spin so if both stop working you have other problems. __________________ o2 prairie 650 supertrapp idsx,dynojet jet kit,Diamond G module & air box snorkle,HL clutch kit,Moose front and rear bumpers(rear mounted upside down, front mounting tabs welded onto frame lower than headlights), 2 inch lift with 28 inch itp 589's,front 2500 lb. winch and rear 2000 lb. winch,60 inch cycle country plow with electric lift and angle. 1964 Chevy Malibu conv. 355 cu.in. 4 sp. two stages of nitrous 850 hp at crank 10.20@142mph. 1970 Chevy Nova 396 auto tubbed and caged. 2000 Ford F350 4x4 7.3 diesel 538 hp 925 lb. torque at crank 1994 HD Dyna wideglide 96 in. S&S custom wheels and paint 1972HD FLH 1200 port and polished heads,sifton cam, aries piston,lightened flywheels,5 sp. in a 4 sp. case trans 1994 prostreet HD sportster 1200 105 hp. 180 rear tire ,midglide front end ,custom wheels,removeable wheelie bar. Special construction 96 cu in rigid, 10 in over springer,250 rear tire,5 sp w/kick and electric start,3 in. open primary,foot clutch hand shift. 08 Skidoo 800 Renagade XP 02 Skidoo 800 Summit He who dies with the most toys dies with an empty wallet(and usually single)

02-08-2010, 11:44 PM	#3
05KawBoy700 Member Feedback Score: 0 reviews Join Date: Dec 2006 Location: MICHIGAN Posts: 64 (0)	You are going to have to pull the diff out and open it up, did you notice any metal shavings in the oil when you drained it? Like greasmonkey mentioned, the clutch packs in the front diff only engage the locker. You should still have at least one of the front wheels spinning in 4wd. __________________ P700 Team Green BF750 Engine Custom 6" Lift N2DeepATV Snorkels Quad Rocks! ATV Stereo EPI Mudder Clutch Kit 30" XXL's Rad. Re-Location

02-09-2010, 10:14 PM	#6
05KawBoy700 Member Feedback Score: 0 reviews Join Date: Dec 2006 Location: MICHIGAN Posts: 64 (0)	That is pretty wierd, and honestly I'd be suprised if the splines on the inside of the diff are still in good shape. You really shouldn't be having that kind of touble at 42hrs. Glad you seem to have found the problem. __________________ P700 Team Green BF750 Engine Custom 6" Lift N2DeepATV Snorkels Quad Rocks! ATV Stereo EPI Mudder Clutch Kit 30" XXL's Rad. Re-Location

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02-09-2010, 02:50 AM	#4
flyalot Junior Member Feedback Score: 0 reviews Join Date: Feb 2010 Location: Beaver, PA Posts: 3 (0)	No, there were no metal shavings. The oil just was really an weird grey color, I've never seen anything like it. Like I said, this thing only has 42 hours on it. Anyhow, I flushed out the differential really good until I got regular colored oil to come out. Now, I take it out and if I put the front wheels on dry ground and the rear on ice, and just put a little pressure on front brake it will just sit there and rear wheels spin spin. If I put all wheels on ice and hit the throttle only the back wheels spin. The only thing different now, if I pull the differential lock in, the left front will grab and go. I know something isn't right but I am stumped. Like I said, up on jackstands, not running, 2 wheel engaged, if you turn either wheel, the other one turns same direction. Put it in 4 wheel, turn one the other one turns oppisite and of course it turns the shaft coming from the tranny. I hate to pull differential but it is looking more and more like that.

02-09-2010, 04:37 PM	#5
flyalot Junior Member Feedback Score: 0 reviews Join Date: Feb 2010 Location: Beaver, PA Posts: 3 (0)	OK, figured it out. The right axle pulled out from the differential. The circlip is missing and the end of the shaft is rounded off. Looks like I need a new shaft. I looked on all the websites I could find and I don't see a separate breakdown for just the part that goes into the diff. Found a whole shaft for $115. I just wondered how this happened and want to make sure it doesn't happen again. Any ideas?

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