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Unread 04-26-2003, 07:27 PM   #1
John Snyder
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front axle disconnect shift fork, broken AGAIN

I have broken my front axle disconnect shift fork two times in the last year. I am always very careful when I shift into or out of 4wd. What else in the 4wd system could be broken that would continue to break this shift fork.....

please let me know if this has happened to anyone else......

thanks

johnny1720

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Unread 04-26-2003, 11:15 PM   #2
sentinal02
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what part of the fork broke? one of the tines? the hole for the shaft? one of the wear clips?
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RIP: '88 YJ 2.5L Ax-5 NP231
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92 YJ 4.0L Ax-15 231
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Unread 04-27-2003, 12:43 PM   #3
John Snyder
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the top hole on the fork

the top hole on the fork keeps breaking...
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Unread 04-27-2003, 07:00 PM   #4
sentinal02
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that means that the collar isn't sliding easily enough, which causes your fork to kick at an angle putting too much bending force for the hole to take. i'm surprised that the vacuum motor has enough force to break that though. try moving the collar by hand and see if it feels like it's binding up. remember, you may have to turn the axle shafts a little to get the splines lined up. if it moves freely, then i would suggest getting an after market steel fork instead of the stock one, if you haven't already. that would be where i would start trouble shooting. HTH
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RIP: '88 YJ 2.5L Ax-5 NP231
Posi-Loked. Herculined. Optima yellow top. 1" Shackle, 2" BDS. Cragar 397's Aussie front.

92 YJ 4.0L Ax-15 231
5" springs, 1" shackle 31's or 35's depending on my mood
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Unread 04-27-2003, 07:14 PM   #5
Gator
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2 options

1. get the cable operated engagment system
or
2. put a Tj shaft on the passenger side & dont ever worry about the Vaccum crap again
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Unread 04-27-2003, 08:27 PM   #6
John Snyder
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where do i get an aftermarket steel fork

I ordered 2 repacement forks from 4wd.com they were really cheap so i got an extra.

I am also surprised that it has enough force to break that stupid fork...


I will be posting pictures very soon of my baby...
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AX15
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Brush Guard
SONY Head Unit
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Unread 04-27-2003, 09:53 PM   #7
sentinal02
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i looked at replacing my forks when i did my posilok, and i found that most places listed two different forks that would work. one was aluminum and the other was steel. are you sure the ones you got were the steel?
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RIP: '88 YJ 2.5L Ax-5 NP231
Posi-Loked. Herculined. Optima yellow top. 1" Shackle, 2" BDS. Cragar 397's Aussie front.

92 YJ 4.0L Ax-15 231
5" springs, 1" shackle 31's or 35's depending on my mood
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Unread 04-28-2003, 04:45 AM   #8
John Snyder
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i will have to call and check thanks

I will have to call and check thanks I had no idea there was a steele one...
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AX15
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3.5 Inch BDS
Brush Guard
SONY Head Unit
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Unread 11-04-2013, 09:37 AM   #9
jojojeep1
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can you replace the wear clips
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