So I tend to use my 4wd very often. This is now the 3rd time that I have actually broken the "shift fork" in my front diff in half to where it will no longer go into 4wd. I was told by GM that this is a common problem, however that there is no aftermarket part for it. And I have looked GM and aftermarket I can no longer seem to find them readily avail.

And before you assume I beat the hell out of it I do not. The second 2 were used from a junkyard where I can only seem to find them. Im not really sure if there is a weak point in them or if I just have bad luck lol.

Any suggestions as to where to find one now? haha

(p.s. its a 96 2dr)

 

I would suspect that you have a problem with the other components in your front diff that are leading to premature failures of the shift fork. It wouldn't take much of an issue with mating of the parts to induce failure of the shift fork. I would look into a replacement passenger side axle tube, stub shaft, collar, and extension shaft to see if that cures your issue.

The shift fork really hasn't ever come up as a failure around here. We have seen a few issues with the engagement collar (what the shift fork moves) or the splines on the extension shaft being rounded over from a partially engaged collar.