thatcabledude
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^ ^ ^ What Broski said. ^ ^ ^You can also slid the drive flange back on install the snap ring and that well give you something more to pull on.
I was concerned about damage from so much force As well, but how can the third member be misaligned it can only slide on in one placeDumb question: I think you said that you snugged up a few of the nuts, but is it possible that the 3rd is now misaligned, preventing the splined collars from sliding? It sounds like you're working alone and would benefit from a second set of hands to thrash around on the 3rd while you're tugging on the axle. I'm concerned that you're going to cause more damage by using so much force.
how can the third member be misaligned it can only slide on in one place
You can modifier a non-locked housing to fit a OEM locker.I was thinking bent studs (which would probably require a bent housing....) or that dent being deep enough to contact the ring gear.
Yeah, with both birfs and the front drive shaft removed, you can drive with the transfer case locked.
I was thinking that the axle housing itself was the same with or without lockers, but there's a different part number for 8/92 - 1/95 with locker listed on Megazip:
43110-60380 Housing Assy, Front Axle FRONT AXLE [08.1992 - 01.1998] FZJ80
43110-60400 Housing Assy, Front Axle [08.1992 - 01.1995] FZJ80 W(*FFA & *DL)
$1,800 for 43110-60400 from McGeorge. Only $1,050 from Partsouq but I bet the shipping quote would be interesting.
Interested in what your concerns would be about the diff centre and the axle shafts? I'm asking because literally just today I just paid $150 for a complete front diff assembly with the exact same thing as the OP - bent housing. It's sitting in my shed right now, and the plan was to strip it for the diff centre, axles, birfs, etc. Any particular things you'd worry about/look for? Bent axle on the damaged side I'm guessing?That took one helluva hit. No way would I try to repair that housing. I wouldn't trust the differential or the axle shafts either. Find a complete used axle assembly and swap it in.
That's what I'm doing currently. I never realized how much faster it is with a hollow front axle and no front DS. I have yet to fill the gas but I bet I'm nearing 14 MPGLittle late now, but you can run that 2wd setup with the axle shafts and bells in place if you leave out the drive flanges.
Cue the part time vs full time 4WD debateThat's what I'm doing currently. I never realized how much faster it is with a hollow front axle and no front DS. I have yet to fill the gas but I bet I'm nearing 14 MPG