AWD Woes Driving Me Crazy

[KingBird]

[HARDTRAILZ]

Glad its working for you.

[navigator]

interesting info on the sleeve and the shaft wear.

[Trail X]

I can only see the splines shearing from a high speed wheel spin scenario that then gets traction.

At least we now know the new fuse. There's always a fuse somewhere, even if it's unintended. I'd prefer those splines over the diff.

[navigator]

I have a spare intermediate shaft, I guess I should hold onto it when I install my AWD sleeve.

[HARDTRAILZ]

I have a spare intermediate shaft, I guess I should hold onto it when I install my AWD sleeve.

Got 2 or 3 spares myself. Never needed to change one.

[KingBird]

[navigator]

Brian, the standard non AWD models have a shift fork instead of the sleeve to engage the disconnect.
A lot of guys here have switched or are in the process of swapping out the shift fork parts for the AWD sleeve as an upgrade to strengthen the disconnect. It is interesting to note that it can basically wear out.

[KingBird]

I'm well aware of that. In my opinion, the disconnect is a piss-poor design, no offense to those that still run them, but it just seems like more shit to break. With the posts I've read, you all seem to be switching to the AWD sleeve and I feel that is wise. I think that if I could switch to a two-speed transfer case and switched 4wd like your TBs, I'd be happy.

[DustinC1989]

I think that if I could switch to a two-speed transfer case and switched 4wd like your TBs, I'd be happy.

Its been done...
EricSS converted his AWD SS to a selectable T-case

[HARDTRAILZ]

Duct tape

[KingBird]

Yes, and bailing wire.

[The Roadie]

...the disconnect is a piss-poor design, ... but it just seems like more shit to break.

Yah, we know. But sometimes it's easier to ALLOW a weak part to remain in the vehicle as a mechanical fuse. I could have installed much beefier and straight (not curved) tie rod ends. I break an OEM curved one every year. But I can change one on the trail in under 15 minutes without removing the tire. If the straight one sent more stress through to the steering rack and it lost a seal or broke, I'd be in a MUCH bigger hurt on the trail. A broken disconnect might save the front diff.

I think that if I could switch to a two-speed transfer case and switched 4wd like your TBs, I'd be happy.

The 2 speed case was on my list of requirements when I got the Envoy inthe first place. I had just come from an AWD GMC Safari van, and even on flat sand, the viscous TC was annoying. Needed true front-to-back locking as well as the Lo range. How did you end up not seeking our a TB or Envoy?

[KingBird]