So I think I messed something up when I switched out my passenger side CV axle last night. I had to replace the axle because the boots were broken and I just wanted it done before winter, I figured I'd replace the axle seal while I was at it. I couldn't get the axle shaft back in easily so I tapped it in with a hammer, It took a few taps on the back of it to get it out so I figured this was normal to go back in but obviously not. Vacuum actuator works and the cable moves freely so it's not that, I'm 99% sure I messed something up inside my diff because even with the cable removed that little pin that the cable attaches too won't pull out. Is it the fork? Please help asap! 4wd worked fine before this but now I have nothing.

 

Did you have the inner axle shaft, (#2) out to replace the seal? If so, the splines on the inner end of the inner axle must be aligned with the clutch gear, (#9). If you force it without the splines being aligned, the shift mechanism will be damaged.

 

Mine looks like this because it's a 1st gen, I had #1 out and it seemed to line up and went in with a few taps. What do I need to do now?

http://www.kylestubbins.com/files/4WD-front-axle.JPG

 

Same basic situation with a little different design. In your diagram: The splines on the axle, (#1) mesh with the splines inside the clutch gear, (#9). The clutch sleeve, (#22) locks #9 and #23, (clutch shaft) together when you select 4WD. The axle tube (#5) will have to be removed so you can inspect #9 through #23.

 

Got the axle tube off and looked in there, the thrust washer (#20 in my link) was bent all up and in a couple pieces. I'm assuming this piece was already broke but somewhat in place but when I slid the axle shaft out (#1) it moved the 2 pieces of the washer and lodged them down somewhere. Ordered a new one from LMC truck. What does that washer do? I pieced everything from the axle tube to the axle shaft back together but without the washer obviously, locked that pin out with vice grips and the 4x4 now works fine (not driving it, just saw that axle shaft spinning in the air)

 

That's a good question. The thrust washer is a bearing of sorts. It rides on the faces of the clutch gear, (9) and the clutch shaft, (23). It keeps the surfaces from grinding on each other and wearing out. In 4WD the 2 shafts are locked together and no grinding can occur, but in 2WD the 2 shafts don't necessarily rotate at the same speed.