Front Axle 4WD Disconnect

[Trail X]

Run it all the way through and smother the screw threads in RTV before assembling. Should be fine.

[priornuker]

Have there been any updates on the rebuild kit from Dorman? Saw it mentioned here several times, but can't find it.

[Trail X]

I'll PM our guy and see.

[Trail X]

Jim said the project hit some snags but it's back on track at Dorman. Still no date, but "not too much longer".

[Hatchet669]

i hope not.. i need to fix my 4wd, and i'm 95% that is where my failure is... even if its not, an upgrade is due.

[dvanbramer88]

This is good ole' America right here, hard working customers working with a company actually interested in serving the customer's needs better. Go Car Guys!




(back to topic)

[VILeninDM]

Hey everyone. So I just had to replace the passenger side CV shaft and while I was in there thought I'd be a good boy scout and go an extra step to check and repack the disconnect assembly.

I read all the posts I could find here as well as trailvoy.com and was extra careful getting the assembly out of the oil pan. What I found worked for me was saturating the entire thing in liquid wrench and letting it soak for the night. Next day with careful prying all the way from 1 o'clock to 8 o'clock with friend applying some leverage at 12 o'clock I was able to barely wiggle the assembly out. One spot seemed extra effective, which was sticking the pry bar as deep as possible at 6 o'clock (directly on the bottom, center of the oil pan hole). So this first part was for next poor soul who searches these boards for tips on how to remove the assembly because his is stuck. Now onto my problems...

After cleaning/repacking the assembly I also cleaned outside of the housing as well as the oil pan hole. Then I applied the grease to the inside of the oil pan in hopes that going in as well as taking it out next time it would be easier. Then I aligned the assembly with the whole and put in the 4 bolts. At first it was going great, I was slowly screwing the 4 bolts in alternating pattern and that's when I made the mistake of thinking the worst was behind me. Apparently, it is very easy to apply too much force as those bolts are tightened and I ended up cracking the outer housing

So assuming I'm able to find a new housing... somewhere, what's the best way to push it back in? Any tips/advice you guys can offer? How safe would it be to take a die grinder the the housing and slightly removing just a tad of metal off it?

Also I tried searching car-part.com for the part, but can't figure out under which name this part would be listed. Anyone have any ideas?

[DirtyBacon04]

I had a few hours of daylight today to play with the disconnect. I wanted to practice a "trail repair" scenario so I didn't pull out the jack stands.

Your truck looks funny w/o anything on the roof!

[Trail X]

So assuming I'm able to find a new housing... somewhere, what's the best way to push it back in? Any tips/advice you guys can offer? How safe would it be to take a die grinder the the housing and slightly removing just a tad of metal off it?

Also I tried searching car-part.com for the part, but can't figure out under which name this part would be listed. Anyone have any ideas?

Hey Dennis, first, welcome to the forum. Thanks for diligently searching before posting!

I think a die grinder would be a fine thing to use without much worry. Make sure you don't take too much off. I think the reason it's 'tight' is because that is the datum alignment feature between the diff and disconnect. If it's too far off center alignment, it could put a bit of a bind in the pass-side diff gear.

I've rebuilt mine twice and didn't run into this issue... the grease on the interference diameter allowed it to be put in and removed without any issue.

On car-part, it will be part of the front differential assembly if I recall. You will probably have to specify once you get in contact with a yard.

[fishsticks]

On car-part, it will be part of the front differential assembly if I recall. You will probably have to specify once you get in contact with a yard.

Front bearing assembly.

[Nakashige]

So Mine Front Axle Disconnect is in pieces and filled with water. Going the atp route was there anything for the AWD one for mods that would have to be done? or is it just install and zip tie the actuator out of the way. Advantages or Disadvantages over the 4wd one

[fishsticks]

AWD = simpler and stronger than the stock one.