1991 pioneer front passenger axle

[Nater Bean]

I have a question regarding some pieces of plastic I found inside the 4wd actuator cover?? I think that might be what it's called. I will apologize in advance for not knowing technical names. Last year I moved the fork over inside the cover to engage the front driveshaft all the time. This worked fine and my 4wd worked fine as well. I accidentally left it in 4 wd on hard pavement and made a right turn and I heard a loud pop and there was a bad grinding noise when I put it in 2wd. I had to leave the case in 4wd so there wasn't grinding but the 4wd was not working. When I got home I pulled the cover and the fork was riding in the 2 axles. I move the fork back over and the 4 wd worked again and the noise in 2wd went away. A Little later while in 4wd I heard the pop again and the same thing happened. When I pulled the cover off I found some small pieces of plastic and there was a little play in the passenger side axle and that axle will still not stay engaged. What are these small pieces of plastic and what can I do to fix it. Thanks in advance.

[shelbyluvv]

It sounds like they are the "pads" off the tips of the shift fork. They probably just wore out from the Center Axle Disconnect (CAD) being locked over. You can go to a junk yard and just pull a nused fork and replace yours.

[Nater Bean]

Not from the forks. I replaced it and when I pulled the old one both pieces were intact. The plastic I pulled out looked to have a circular shape to them.

[shelbyluvv]

Like they say. A picture is worth a 1000 words. Pics are always better than trying to figure out what someone is trying to explain over the internet.

[yxmj]

There is a plastic dust shield that should be on the outside of the axle tube

 

This on is off a ZJ but you get the idea.....could it be this

 

Maybe it was broken and driven in some how?

 

Or installed incorrectly? 

[Nater Bean]

Yes that looks like some of the pieces that I pulled out. I'll pull the axle and see what I can find. Thanks