Front axle shift fork????

[Ghost]

Ok was working on the front shaft hitting the tunnel on the 84 XJ yesterday and thought I had her ready for some wheeling. Was testing it in the sand next to the shop and noticed the front axle was not pulling. So I determined the front disconnect was not working. Pulled the disconnect to find the shift fork broke :shocked:! Replaced it with my spare and went to test it again. Worked fine In 4WD but when I shifted into Low it stopped imediatly! First will a bent axle causse them to brake and how do I tell if it's broke. Second, will the DS hitting the tunnel cause a shock to the front and break it? Third is there a steel replacement? TIA! 94 Drivetrain in an 84!

 

[satan]

Cast iron fork part numbers:
Dana #41553 or Mopar #4137727

Fork clips/wear pads part numbers:
Dana #621059 or Mopar #4137731

What's breaking? (the fork or where it fits on the actuator shaft) -

The fork can 'float' a considerable amount (up and down" and the disconnect collar can slide in and out of the fork a LONG way before stuff starts breaking in there... Most of what I see looks to be from thrust - like the splines are thrusting the collar towards disconnection under load - usually a worn collar or twisted/worn splines...

 

[8Mud]

I´ve never had one break, but I have had them engauge with a load bang and on occasion, pop back out of engauge. I found a vacume leak, that seemed to help, the next time I tried to engauge the axle. Also sprayed some oil, into the vacume nipples, into the insides of the actuator, seemed to also help. Seemed the more I used the disconnect the better it worked.

 

[Ghost]

The shift fork broke at the base of the fork. Not the fork itself but about 1/4-1/2" from where it mounts on the vacume motor. My thought about the axle is b/c my front tires are leaning in at the top way too much. Do you think the iron fork would hold up better? I did nto see any spline damage but when I pull this one I'll look. What about welding some angle to hold the color in place but that will not interfear with the shafts?

 

[Rev Den]

I broke mine when trying to engage it with 1 front wheel spining and 1 stopped.

Rev

 

[BUCKYXJ]

I have broke two so far and now I just used a hose clamp on the vaccume accuator to hold it in place till I weld the front and go to cable accuated. Mine broke in the same place yours did. Cast Iron is the way I am gonna go when I do the cable system. DIG IT!