by v7guy » Mon Mar 24, 2014 6:09 am
Well the AWD has no disconnect, it's remotely possible that the bearings that support the CV and the intermediate shaft (the piece that goes through the oil pan) are worn. But that wouldn't cause you to have no power to the wheels. In the AWD the transfer case puts power to the front and both Axles are permanently connected by the sleeve... as a side note that's reason many of us has put the AWD sleeve in our disconnect, it removes one more mode of failure and spreads the load across the bearings of the intermediate shaft and the CV more evenly in the "disconnect housing" and at less of an angle.
So your basically down to two options here since you said the front driveshaft is turning...
One, both CV shaft tripots are broke/tripot stubs broke/intermediate shaft. I've seen a cracked tripot before (not on our vehicles) it should of been so obvious that you wouldn't of missed it. in this case the diff would be turning but the CV wouldn't
Two, the front diff is internally in pieces. Pinion and or ring gear missing teeth. If the front diff is getting power and neither CV shaft is (and they aren't really broke) then there's pretty much only this left.
You said earlier you put new bearings in the front diff, new bearings require a different preload on the pinion 14-19 inch lbs new vs 6-8 inch lbs used, you also have to realize that setting the when setting backlash just a 1/16th of a turn can change it by a good lil bit... "this is the number of turns it was at" isn't the way to do it.
You also stated it had no oil in it. Did anything else look amiss in there? Generally new or used, you're suppose to use a new crush sleeve every time. Given that you said you heard a nice crunch crunch, pop pop after feeling binding and then the binding stopped and eventually the crunch and pop stopped I'd be inclined to think it's time for a look at the inside of that diff.
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