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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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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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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(Applications – Ford Mustang, Crown Victoria, Ranger, F-150, and Explorer)
NOTE: Be sure to keep right and left bearing cups, shims, and bearing journal caps separated!
1. Install ring gear on Torsen differential. Torque bolts as specified in the Ford Service Manual.
2. Install two new journal bearings on Torsen differential.
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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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For the first time, Ford is using a front-wheel drive in a middle range vehicle. For this reason, the well-proven MTX 75 transmission from the Fiesta/Escort has been modified and adapted to the requirements of the Ford Mondeo. At the same time, a 4×4 version is also offered, in which the MTX 75 transmission is extended, as on the Escort 4×4, by a transfer box. The transfer box in the Ford Mondeo is a new development and effectively transfers the higher torque to the front axle. This brochure describes all new features and modifications implemented on the MTX 75 transmission compared to the MTX 75 transmission of the Escort ‘91 as well as on the MTX 75 4×4 drive concept and vehicle compared to the Ford Mondeo with front wheel drive.
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Vehicles application: Chevrolet P-30 & GMC P-3500
The axle has a banjo-type housing with a removeable carrier. The drive pinion is straddle mounted on removeable carrier. There is no adjustment for drive pinion depth or bearing preload. The preload on the differential side bearings is set by adjusting nuts on which the bearing cups rest. The differential has a two-piece case and four differential pinion gears.
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START WITH THE REAR BAR
1. Drive the vehicle onto a 4-post lift or floor ramps. THE CAR NEEDS TO BE AT NORMAL RIDE HEIGHT FOR PROPER INSTALLATION. You cannot have the suspension hanging while installing this bar!
2. Once vehicle is raised, take a moment and observe the stock rear bar and the way in which it is mounted.
3. Release rear exhaust hangers and middle hangers then let hang. (ok to use small amount of WD40 to loosen) Or, you may unbolt the hanger brackets using an extension and 13mm socket.
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INSTALLATION OF HOTCHKIS FRONT STABILIZER BAR
1) Please look at the original front antiroll bar and note the orientation of the front bar. You will want to install the new Hotchkis bar in the same manner.
2) Securely block the rear wheels of the vehicle. Use a jack to raise the vehicle and support with jack stands.
3) Remove the factory plastic undertrays from the car with a 10mm socket on the bolts, and a small screwdriver to pry open the plastic trim plugs.
4) Disconnect the endlink from the stabilizer bar using a 14mm wrench.
5) Using a 14mm socket and extension, remove the factory frame brackets. Then remove the stock bar from the vehicle.
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