Any help or opinions are greatly appreciated, I have a 2008 Sportsman 800 with 1200 miles of light use, I have owned since new. Due to a 4wd problem (constantly locked in) I took out my front differential hoping to find the common blown up sprague cage, well that I did not. Every thing appears to be in great condition and intact other than when I took it out the output pistons and parts on the drivers side I found wrapped around the output pistons was a bunch of black plastic material. It appears the piston was rubbing against the black plastic ring section that comes as part of the case on both sides. I assume it is some type of a coil or something? Not sure if this is supposed to be touching or not. It almost seems like in a manual transmission you have the flywheel and pressure plate that might be slipping causing it to melt off instead of making full contact? Just not sure how these 2 parts are supposed to mate or not touch at all. I assume the 4wd is locked in because of the mess that I found. If you look at the second pic I also have 2 pretty good grooves worn in the armature piece not sure if this is supposed to happen? I posted a few pics first should show the wear/melting on the whatever its called, second shows the mess on the workbench and third shows the melted pieces that are from the first pic. The passenger side does also have some wear on it but no real debris. Thanks to all who can help and hope I put this in the right section. If not please advise.
