Use this definitive 4-wheel drive front axle engagement guide to understand, diagnose, and repair those mysterious 4-wheel drive front axle issues. This guide explains how the OEM units function, what causes them to fail, and which corrections are available. WHAT IS 4X4 POSI-LOK? 4×4 Posi-Lok is the patented cable activated engagement device designed to replace the failure prone vacuum and electric front axle engagement systems. 4×4 Posi-Lok is not a posi-trac or locker. 4×4 Posi-Lok is simple and easy to install and allows you to engage your front axle from inside the cab. Posi-Lok guarantees that your 4-wheel drive will engage every time because you are in direct control of front axle engagement. A one inch pull of the 4×4 Posi-Lok cable ensures you will have 4-wheel drive when you need it, as long as the transfer case is engaged.
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This article covers front axle shafts on FWD and 4WD vehicles. Intermediate axle shafts are covered at end of this article. See RWD AXLE SHAFTS article in this section for rear axle shafts on Celica and Camry All-Trac and MR2.
REMOVAL & INSTALLATION AXLE SHAFTS
Removal (Camry)
1) Remove hub cap, cotter pin and lock nut. Loosen and remove lock nut from wheel bearing. Remove engine undercover. Remove front fender apron seal.
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Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4×4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures.
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This article contains underhood views or schematics of vacuum hose routing. Use these vacuum diagrams during the visual inspection in F – BASIC TESTING. This will assist in identifying improperly routed vacuum hoses which cause driveability and/or computer-indicated malfunctions.
1991 ENGINE PERFORMANCE Vacuum Diagrams Camry, Celica, Corolla, Cressida, Land Cruiser, MR2, Pickup, Previa, Supra, Tercel, 4Runner.
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Before continuing with the  installation, here are a few definitions you should be aware of:
Initial Timing: This  is  the  base  timing  (also  referred  to  as  idle  timing)  of  the  engine  before  the centrifugal  advance begins.
Centrifugal Advance: The centrifugal (or mechanical) advance mechanism is made  up of weights, springs,  advance cams, and an advance stop bushing. The amount and rate of  advance that your distributor  is capable of is determined by the centrifugal timing.  If you ever wish to lock out the centrifugal advance, refer to the centrifugal advance section. 
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This kit is designed to work with 15” or larger wheels.
Instructions:
1. Disconnect the rear hard lines on the rear axle from the wheel cylinders.
2. Disconnect the rear brake hose from the hard lines on the axle.
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Installation step the front wheel bearing for Ford Transit:
1 Remove the wheel hub (refer to the manufacturers instructions).
2 Place the bearing separator under the bearing assembly, making sure the flat side is facing up and under the bolt holes. Tighten the bearing separator by turning the nuts evenly (fig.1B).
3 Place the puller insert into the centre of the hub, see fig.1A.
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There are three alternatives when thinking of axles:
1) ‘English axle’ Standard production axle on all Escorts including RS products. Reliable but prone to bending in very rough events. Produced as homologated axle for RS2000 in Gp 1. Wheel arch extensions not necessary, but also excellent choice for cheap Gp II car.
The Capri derived Atlas axle is no longer available as a new part. Gp 4 axles with their bracketry for Gp 4 suspension can be made up or are available from Rallye Sport Dealers.
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Instructions: There are four M10 countersunk bolts supplied with this kit.
2 x M10 x 40 (Standard Thread)
2 x M10 x 1.25 x 40 (Fine Thread)
These bolts are used to mount the upper brackets to the chassis. When the bump stop is removed the threaded hole must be examined to determine if it is a standard or fine thread.
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Removal & Installation WARNING Do not loosen the axle wheel hub retainer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE Have an assistant press the brake pedal to keep the axle from turning. 1. Before servicing the vehicle, please familiarize yourself with safety procedures.€ 2. Remove the axle-to-wheel hub retainer nut and washer.€ 3. Remove the parking brake shoes. WARNING Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components can result.€ 4. Press the outboard CV-joint until it is loose from the hub.€ 5. Remove and discard the toe link-to-wheel knuckle nut. WARNING Do not damage the boot while separating the toe link from Read the rest of this entry »

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