Yet Another Bad Front Axle Disconnect

[HawkTown28]

So a few weeks ago here in Michigan we had a pretty good snow storm that lasted a few days and much snow accumulated. When the storm was predicted, I was happy to know I would have no problem because I have 4x4.....at least I thought I did. I woke up one morning to go somewhere(before the storm but still snow on the roads), I put it in 4x4 and pulled away, to find only my rear wheels were spinning. I tried everything to get it to engage but nothing worked. Needless to say I was not happy. So I went through the 4x4 diagnostic sequence and determined that my front axle disconnect was not engaging. So I got online and ordered a new complete unit. Weird thing was that the day before it was working perfectly fine, then the next not. I was able to remove the actuator and force the sleeve over the splines and then I left it in A4wd to keep it from coming back out and then put it in 4wd when needed just to get me through the storm.

After doing some reading I determined that I could do the job. Disassembly went very smooth and only took about 45 min. Everything came apart with ease....... Then it came time unbolt the disconnect assembly and pull it out. Bolts came out easily, but the unit would not pull out from the oil pan. No matter how hard I pried on it wouldn't budge. It was seized really bad somehow. So basically it started to come out in parts. The outer bulge part was first to break off. then I removed the outer half of the case. Then pried on the inner case and it snapped off leaving the sleeve and inner bearing in the oil pan. Long story short it took a lot of cautious drilling and wailing on it with a hammer and pry bar in an attempt to remove part of the ring to relieve pressure on it. Once that was accomplished the rest of the ring pulled right out. After that everything including the new unit went back together with no issues and the 4wd all works good now.

This was first to come off....


Next was the outer case....


Then the inner case half snapped off....


After some drilling the inner sleeve came out....


Surprisingly the shift fork which I thought would be the problem was fine....


upon further inspection this washer thing is heavily worn and bent....


And also the inside of the case was pretty much almost worn through....

[The Roadie]

Thx for the report and pics! How many miles were on it?

[v7guy]

Sounds about par for the course for many of us, glad you got it fixed up.

[DustinC1989]

Guess I caught mine early, outer seal and the sun washer were all that needed replaced. Never even put a mark on the CV

[Trail X]

That's the key, early spotting of the trouble helps prevent the wear to the aluminum housing. Once you have serious wear on the aluminum housing, you either have to get the sleeve, or you have to replace the whole thing. If you try to reuse housings with wear on them, you'll only wear out your gears that much faster the next time around.

Thanks for the pics!

[TBYODA]

That's the key, early spotting of the trouble helps prevent the wear to the aluminum housing. Once you have serious wear on the aluminum housing, you either have to get the sleeve, or you have to replace the whole thing.

Any suggested mileage to maybe pull parts and inspected for us "new guys"? Thus staying a head of the curve.

[Trail X]

Inspect by pushing up and down on the tripod casting and checking for play. More than like 1/16" and you probably need to tear it down and at least regrease it.

[ErikSS]

Any suggested mileage to maybe pull parts and inspected for us "new guys"? Thus staying a head of the curve.

If I remember right, my truck had around 65,000 when I installed the ATP. I didn't get to see it but the Trans shop was shocked that it was in such bad shape. So... 50,000-60,000 would be my recommended first check.

[TBYODA]

Inspect by pushing up and down on the tripod casting and checking for play. More than like 1/16" and you probably need to tear it down and at least regrease it.

Thanks.

Any suggested mileage to maybe pull parts and inspected for us "new guys"? Thus staying a head of the curve.

If I remember right, my truck had around 65,000 when I installed the ATP. I didn't get to see it but the Trans shop was shocked that it was in such bad shape. So... 50,000-60,000 would be my recommended first check.

I am at ~71k guess I we'll be checking it out soon. Was thinking I should check it now.

[mikekey]

Yeah.... reading this I don't know if the Trailblazer is ever going to get out of the garage, lol.

[Moots1288]

I wish I was making progress I just have a parts pile and wish it was atleast 20 degrees so I can work

[ErikSS]

Yeah.... reading this I don't know if the Trailblazer is ever going to get out of the garage, lol.

Why? Lol

[Wahugg]

I don't know if there is any set distance where these things go bad.

Just for reference, I have 162,xxx miles on my TB and have had no issues or excessive play. I've always meant to take it apart and inspect it, but the possibility of fracturing the housing is too much of a risk for me with no ill symptoms.

-Wahugg

[TBYODA]

We'll I was not going take apart just check it out like James suggested and go from there. Wahugg you got a disconnect that was made on Tuesday or Wednesday.

[seantrost]

Mine was at 145,000 when it was removed.
Sean

[Moots1288]

I installed the AWD sleeve at about 90,000 and the inner and outer slipped right out of the pan as one unit.

[Trail X]

I've always meant to take it apart and inspect it, but the possibility of fracturing the housing is too much of a risk for me with no ill symptoms.

That's a bad reason in my book. If you get to that point and it doesn't want to come out, then just take off the bolts that hold the housing together. At least take it apart and inspect it. If you aren't lifted, I could see it possibly being ok, but if you're lifted, you're going to see wear, it just depends on how long you've been lifted.

[ErikSS]

I see James point. However, I typically function more like Wallace. If it isn't showing any signs of wear, why spend time and money on it....
(if it ain't broke, don't fix it)

[Trail X]

The reason is found in Mario's last TECORE trip. He didn't think he had any issues. But because it wasn't connecting, he ended up busting his rear diff, and then had to be towed out, and limp home, and leave TECORE early.

Don't leave TECORE early... check yourself before you come down with a case of mydisconnectsuxalotis. Preventative maintenance is a good idea, especially on an item that we all KNOW will eventually stop working.

[v7guy]

Haha, you're crackin me up James

Erik, it would definitely behoove you to seperate the halves and grease up that bad boy. There's basically no chance of breaking anything and it'll help it live a longer happier life.



Michael, you'll find how common your experience is here

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