CAD Axle Won't Line Up
 

I can't find a similar problem after searching these forums. My CAD will not engage because the outboard axle does not meet with the intermediate. I took the plate off the actuator and the the outer axle is hanging down about 1/4 inch so the collar can't ride over it to connect. I understand that there is a "nose" projection on the intermediate axle that slips into the outer axle to keep them aligned. Apparently this is worn down or is something else responsible for this sag in the outer axle? I can manually slide the collar to engage the axles and then disable the vacuum. Would that do any harm to drive that way? I drive the truck very little.

There actually is a plastic bushing that slides over the "nose" projection you mentioned. If this is damaged or broken then your 4x4 wont engage because the axles are misaligned. I believe you can slide the collar over both axles, but it will be a sloppy connection and can damage your axle seal and maybe even your collar. Its probably best to just replace the bushing. I replaced mine about a year and a half ago, wasnt too bad, but had to take a lot of stuff apart.

Ok . I didn't see anything of a bushing. I'm having trouble finding a web site with a break down of the parts needed . Do you know where I can find that bushing? And do you know what the needle bearing is and the part it plays?
Also, the pads on the fork are long gone and the fork is worn down as a result of the condition I have.

Quad 4x4 sells them. The p/n for my truck is QK4625. I would think most years would be the same, but you should double check to be sure. This is the bushing and the needle bearing that supports the intermediate shaft.

Okay. Thanks very much. I'll check it out.