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Old 02-24-2010, 10:36 PM   #1
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Default Free Front Axle CAD Bypass (-91 Writeup)

I figured this would be useful with all the questions around lately. Mods, if you find it "worthy" you can move it to the writeup section.


I got tired of not having 4wd today and decided to lock my axle disconnect over. This locks the 2 pc passenger side axle together essentially making it like the 91+ models with the 1pc axle. This way you will not have to wonder if your front axle is locked in just put it in 4wd and go!

It is very easy to do and I would say it takes about an hour.
The only tools required are a 11mm socket, jack, some gasket maker, gear oil, and something to get the c-clips on/off.
Jack up the passengers side and locate your CAD assembly. It is the weird looking piece on the passenger side axle tube with three vacuum lines running to it. Yours (hopefully) wont be as dirty.

Click the image to open in full size.
Next step is to put a catch can underneath it, get your 11mm wrench/ratchet/whatever and loosen the bottom two bolts a few turns. Allow most/all of the gear oil to run out (a couple ounces). You can now remove all four bolts.

Once you have the disconnect assembly off, clean it up and get something around to remove the C-clip. I honestly think the removal of the C-clip was the hardest part. Be careful as it WILL go flying and be hard to find.
Click the image to open in full size.

Move the shift fork over past where the clip usually rides and then reinstall the clip. Your shift fork is now in the "locked" position.
Click the image to open in full size.

For the next step, go back out to your jeep. You will need to move the locking collar over into the "locked" position. You may have to rotate the tire to get the splines to line up. You will know you have it if the driveshaft spins when you rotate the passengers side tire.
Click the image to open in full size.

Clean the mating surfaces of the shift motor and axle disconnect area. Install a thin bead of RTV or gasket maker of your choice. (I got away without using it, but its highly recommended)

Install the shift motor being sure the fork lines up with the collar. Tighten the 4 bolts in a criss-cross or hex pattern a little at a time being sure not to tighten them too much and strip the holes out.

You are done! Check your gear oil before your first ride, you may need to add a couple ounces since some was lost when the CAD assembly was taken off. I plugged the vacuum lines with some screws, but Im not sure if my 4wd light comes on now.

So far I have had no bad vibes or extra noise from the front driveshaft rotating. Keep in mind this is supposed to be a "temporary" fix, but I have heard of people running this way for years. My 4wd now works like it should and I am very happy overall with it.


Note: pictures where taken from Google, and a few where taken from Dodger889's writeup on Jeepforum.com
I had PMed Dodger at the time but have not received a response.

Last edited by 89Laredo; 02-24-2010 at 10:45 PM.
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Old 02-26-2010, 10:23 AM   #2
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break a bolt?

i may do this if my actuator doesnt work.
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Old 02-26-2010, 11:31 AM   #3
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Nope, my bolts held up fine. Theyre not on very tight anyway.
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Old 02-26-2010, 12:47 PM   #4
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that's nice, but you're gonna want something a little stronger to hold that collar over. that clip won't do it on it's own. you can use a pile of washers to fill the gap so the collar won't pop over, snapping the clip under pressure.
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Old 05-31-2016, 03:37 PM   #5
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Does this mod cause any future problems? Like the extra stress on the front axle gearing and such? Also, what do you mean by plugging the vacuum hoses.
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Old 05-31-2016, 04:29 PM   #6
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Quote:
Originally Posted by Bucaslaker View Post
Does this mod cause any future problems? Like the extra stress on the front axle gearing and such? Also, what do you mean by plugging the vacuum hoses.
No!!! Do you think we're BSing you or something? Get it done!!

CAD STINKS


The big issue is that the CAD system only fails when you need it the most.

Kinda like when you don't realize your wiper blades need replacing until it rains....

I know somebody’s system works and he advocates keeping it stock, but my exposure to the failures is probably hundreds of times greater than his, as a result of being Service Manager at a Jeep dealership from 1980 through 1992, and being a current XJ and MJ owner.

CAD stinks. Every Jeep I work on with it, I eliminate it. Guess what I find in the process? 25 year old busted vacuum lines, bloated vacuum line connectors, bad vacuum reservoirs and piping, bad transfer case vacuum switches. In other words, had the person gotten into a sticky situation and needed 4WD, they would have been screwed!!!

That's the tip of the iceberg. The factory went through 3 revisions of the shift fork also. The fork issue is non-existent if you just slide it over and leave it.

See the link below for complete instructions. Takes less than 1/2 hour.

http://www.cherokeeforum.com/f51/fre...ss-91-a-38629/
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