Easy, free axle fix?

T

Tommy4949

NAXJA Forum User
Location
Ogdensburg, NY 13669
I put this on the modified section because my Jeep is definitely modified and I am not trying to fix this thing in a stock manor.

I have a 1990 front axle disconect D30 in my Jeep. The little pads on the shift fork wore off and the front axle will not stay locked in 4wd. The dealer says they don't sell the pads by themselves anymore, but they do sell the whole fork with pads for more than I have to spend.

I should say that I have slide the fork to the locked position and put a hose clamp around the shaft to keep it from unlocking. This is working just fine.

I plan on rebuilding the front axle within the next 2-3 months with front shafts out of a 2000 XJ, so I don't want to spend any money fixing the disconnect on this axle. Plus I don't have the money to spend on new parts that I don't need anyway.

I just want to rig something up to get me through until I rebuild the axle. I still want to be able to hit some mud and moderate trails without the front axle poping out of 4wd.

Does anyone have any tricks I can do to get me through the next 2-3 months? I really appreciate whatever ideas/experiences you guys can offer.
 
Have you tried hitting a junkyard to get the axle shaft from a ND 30 and then removing the actuator and sealing it off?
 
dave92cherokee said:
Have you tried hitting a junkyard to get the axle shaft from a ND 30 and then removing the actuator and sealing it off?
Click to expand...

Yes, that's what I will be doing in 2-3 months. I just need something to get me by until then and not cost more than a few bucks. If I could get some pads some where, I would be all set. Junkyards only have the ND 30s, the older ones have all been crushed since all that stuff has rusted out long ago.
 
Convert it to a solid shaft, you will need the proper seal, and you can probably find a shaft at the salvage yard or for sale on-line cheep. See pg 72-73 in the XJ builders guide, if you don't have one get one....it's worth the $26 bucks
 
Locking the fork in, with no pads will cause it to wear out quickly. It will be metal on metal with the shift fork being the thinner of the two. I have seen it happen on unimog axles (same style disconnect for the locker)
 
just shim the fork with a stack of washers, theres a couple of writeups on here about it. I did that and it worked fine.
 
Rockslut said:
Locking the fork in, with no pads will cause it to wear out quickly. It will be metal on metal with the shift fork being the thinner of the two. I have seen it happen on unimog axles (same style disconnect for the locker)
Click to expand...

I do appreciate the replies guys, but this is the only response that is even close to being on the right track.

Here's what I am trying to do...
  1. Fix it for under $10
  2. Get 4wd with my current setup just for a few months until I can upgrade to a solid passenger's side shaft.
Can anyone help me out with a cheap temperary solution?
 
Look at the post directly above yours....
 
Well, I got the pads. $0.75 for each pad plus $3.00 S&H. EDIT: These http://www.4wd.com/productdetails.aspx?jeep-sid=353&plID=322&partID=9428

I couldn't wait to have 4wd again, so I installed the new pads the same day I got them after work.

Well, last weekend, I went into a mud hole just to have the front axle immediately disconnect.. This resulted in a 45 minute game of getting out of the mud hole in 2wd until I finally resorted to using the winch on the nearest tree 130 feet directly to my left..

I finally got to look at the axle today and found that one of the pads was hanging off it's perch and the other was spinning around with the collar and not even connected to the fork any more.

The pads are barely holding in place and 20 minutes in 4wd knocks them loose again.

Is there a cheap way of getting these pads to stay on the fork?

They are a ceramic or hard plastic sort of thing so I know I can't squeeze them so they stay on like I could it they were metal. I need my 4wd so I can have fun this summer. I plan on rebuilding the front axle with one piece shafts this fall or winter so I don't want to spend more than the $5 like I spent on the pads.

TIA, some guys from the local 4wd club are going out mudding this Saturday and I really want to make it in my Jeep. I bunch of them are leaving for Iraq soon and I would like to go wheeling with them before they leave.

NOTE: Axle disconnect is NOT functional, I used a large hose clamp on the shaft to hold the fork in the locked position. This is working fine with very little play in the fork. It's the pads popping off the fork that is allowing the collar to slip past the fork disconnecting the front passenger's side axle shaft.
 
Last edited:
Good question! I've never had the misfortune to have to replace the pads, I just knew that 4wdHardware is about the only place I've been able to find disco parts. I would assume they are held on by some sort of glue. I've seen a lot of the forks & did not even realise you could replace the pads untill I read up on posi-locs & they suggest you replace the fork or at least the pads.I would try JB Weld or epoxy, not as fast as super glue but lots stronger.good luck.
 
just replace the shaft now. if you're that broke you shouldn't be out wheeling.
 
IslanderOffRoad said:
just replace the shaft now. if you're that broke you shouldn't be out wheeling.
Click to expand...

You're right. Look for my next topic with my rig plus spare XJs for sale.:bawl:

I'm not a check book wheeler as some people might be. As a friend of mine said, and I quote, "I'm just a caveman, I solve mechanical problems in the simplest/cheapest fashion possible with the tools I have available."

To Chuck, thanks for the advice. I had thought of that, but I was concerned that the pads would flex under acceleration in 4wd and crack the JB Weld and possibly get into the diff gears. I thought of using something flexible like gasket silicon or a rubbery glue, but I don't know. I will try to find out if they use something at the factory to hold them in place. I thought they just snapped in place and stayed put.
 
Tommy4949 said:
You're right. Look for my next topic with my rig plus spare XJs for sale.:bawl:

I'm not a check book wheeler as some people might be. As a friend of mine said, and I quote, "I'm just a caveman, I solve mechanical problems in the simplest/cheapest fashion possible with the tools I have available."
Click to expand...

I'm not a checkbook wheeler either.

I just picked up a set of 297x shafts for 25 bucks a piece. We're not talking high dollar parts here. I'd be happy I could still daily drive the thing because its not a necessary component thats broken, save up the cash, and not worry about wheeling until I could fix it.
 
IslanderOffRoad said:
I'm not a checkbook wheeler either.

I just picked up a set of 297x shafts for 25 bucks a piece. We're not talking high dollar parts here. I'd be happy I could still daily drive the thing because its not a necessary component thats broken, save up the cash, and not worry about wheeling until I could fix it.
Click to expand...

I was trying to trade my car stereo system for a rear 8.25 and front 297x axle shafts but the guy has been dragging his feet to do the trade. I also have two sets of 260x one piece shafts in my two parts Jeeps, I just don't have the time to do it right now. I get maybe one day a month for myself without the old lady and kids, so I like to spend it wheeling. Around here the summers are short so I want to spend as much time playing as I can, I have roughly 8 months of winter to work on the Heep:D
 
You must log in or register to reply here.

Similar threads

B
My front wheel has negative camber
Replies
2
Views
336
Tim_MN
Tim_MN
Jeepin_JD
92 XJ Sport - Resto Mod
Replies
17
Views
431
Jeepin_JD
Jeepin_JD
D
Welding rear axle - Potential damage question
Replies
8
Views
589
Evan03
E
sdspearo
Using a case spreader on a trussed axle?
Replies
9
Views
450
sdspearo
sdspearo
D
Locker / Posi combo for trail rig
Replies
13
Views
696
Evan03
E
Back
Top