Hub actuator fork problem

[newjeeper]

I was ready to put a home made posi lock on my 91 wrangler but when I took the cover off the axle where the vaccum system is to lock the hubs, most of the fork is missing. There are pieces of it in there but most of it is gone. What would make it shatter like that? Where can I get a new one? Is it worth getting a new one? I'm a newbie when it comes to jeeps so I need all the help I can get. In my other post someone wrote that I should change out the axle and someone else said the axle in it now would work fine since I'm not going to use it for hardcore offroading. What about manual hubs? Any help you can give me will be greatly appreciated.

[mullins87]

You have two options, well , actually three. Option number one; Get a replacement fork. I've seen them at Quadratec and other places. The cheapest option. Option number two; Replace the passenger side axle shafts with a one piece axle. Then make a square metal cover to replace the vacuum disconnect. A little more expensive, but the most effective considering the cost. Option number three; Replace the entire axle with a non-disconnect model. By far the most expensive and labor intensive.

[XJStewbob]

just go to the junkyard or pull a part and get a stock shaft (long ) and replace the 2 peace and be done with it

[John]

In the past I've simply tacked the colar into position on one side of the shaft to keep it locked. Then just put whatever kind of cover you want over the hole. The down side which is why I only tack the colar in place is that if you break the shaft you'll have to remove the colar to get the shaft out. There are a lot more 2 piece shafts available used for replacement than one piece.

[newjeeper]

In the past I've simply tacked the colar into position on one side of the shaft to keep it locked. Then just put whatever kind of cover you want over the hole. The down side which is why I only tack the colar in place is that if you break the shaft you'll have to remove the colar to get the shaft out. There are a lot more 2 piece shafts available used for replacement than one piece.

Does that hurt anything if you drive it around on the road like that? It sounds like an easy fix. I have access to a welder (well, that's what I do for a living) so it wouldn't be hard to do. I don't want to spend too much money on this right now because I'm having problems shifting now too. It doesn't like to go into gear. I have to pump the clutch a few times to get it in first and double-clutch after that.

[John]

It wouldn't be any different than putting in a one piece shaft. The only concern may be if you have a locker in the front, it may cause some tire wear or reduce your turning radius. If it's a regular open diff you'll never know any different.

Just don't forget that if you have to take the shaft out you'll have to break those tacks first. All you need is enough to keep the colar in place.

[kids88yj]

I have a complete 4x4 posi with gasket and fork for $50. Worked fine no issues, Im swaping axles and wont every need it. New they are around $200!!