Well just got done installing a posi-lok kit on my 98 4x4. Everything went together great but when I tried it out, it will not engage the front axle. I can't even pull the switch it out. It is like the collar is siezed up or something. Is this possible? I noticed when it was apart that I couldn't move the collar by hand but didn't think much of it. What do you guys think?

 

I think that you already answered your own question.
Pop the cover back off and look at the collar and splines on the axle. If ther is a lot of rust you will have to get it all off, try a good penetrating lube spray it on really good and let it sit over night, then try go get the collar to move by hand.

 

does the axle need to rotate at all to get the splines to line up? haven't seen the inside of the collar arrangement yet myself, but it was a thought!

 

One more thing before you crack open the cover. Like said above did you try to shift is while moving? If not try that at a very low speed.

 

First thing is first...

the collar should be allowed to move freely, When i did mine, i had no issues with moving the collar. The stock OEM vac system does not produce much vaccum to get it to move..

If you couldnt move it, id say it was rusted in. Try freeing it up as it has been suggested, My kit engages smooth as silk in slower speeds. The gears need to properly align (it helps to be goin perfectly straight) so that the switch can pull the collar over the left shaft and get ur 4wd to work...

ALso u might wanna check that you have the little c clips on both of your points where they go, if you forget one you might not have 4wd...

Rick

 

before trying while driving, lift the right tire off the ground and have a friend spin it by hand slowly while you try to move the collar. WAY less chance of trouble this method!

 

Thanks for the replies. I have taken the CAD housing off and the collar was stuck. Broke it loose fairly easily. Soaked everything in penetrating lube for a while. I then jacked up one side and tried engaging it by hand. It will go in fine but when I slide the collar back to disengage 4wd it sticks. It takes all the pressure I can put on it with my hand to get it loose again. If I unstick it and put the CAD housing back on I can engage 4wd once really easily and then take it out easily. Then the collar will stick again and I have to pull everything back apart to unstick it. I am really fed up with the whole CAD system, but do not have the money to sink into a Ford dana 60 or a lockout hub conversion. Any ideas?

 

Hmm

OK, im thinkin that the collar could have already gone bad, or the shift fork could be worn out. I have only seen one case, where the collar went in rather bad, and it got stuck at a slight angle, A worn collar, or a worn shift fork could be a culprit. But in this case i think its more a worn out collar. It is also possible that the teeth are slightly stripped from possibly too much TQ to the front axle...

Or if it gets stuck, double up on the C clips on both ends of the shift fork, and try that again...

Rick

also