Dealership Installed CV Axle Slid Out of Differential

2012 TRD OR, 156k miles (awesome reliable truck, well maintained, bought brand new in 12).

I noticed CV Axle boot leaking last week. I took to local Toyota Dealership. I picked it up yesterday and drove it 25 miles home. When I arrived home I could smell burning oil.

Oil coated pretty much everything underneath, rear wheel well, splatters on rear bumper, and was burning on the muffler. I discovered the brand new CV axle had slid out of the front differential by about half an inch.

I'm not sure at what point on the way home that it started leaking fluid. I didn't notice any vibrations or sounds.

I visited the dealership this morning and their service manager is "in a meeting" and the service rep said he would call me back with next steps. I never received a call back. At the end of the day I called back and was told by the service rep that I should get it towed in. I pushed back saying that this was caused by them why should i have to line up a tow truck. I then asked to speak to the General Manager. After a long wait, service rep comes back on the phone and says the General Manager is "in a meeting and cant talk to me." Service rep then proceeds to say he will have a tow truck pick it up in the morning from my house.

Since the front differential likely was ran with no fluid for all or part of the 25 mile drive home what suggestions would you recommend as to how the dealership should take care of this issue to make it right? I don't want to be responsible for replacing a front differential now or in the future as a result of this.

 

There’s still fluid in there.
I wouldn’t worry about it.
The spider gears are all that is turning, and the fact that the fluid came out is a “good” sign.
At least you know some made it up to and down into the bearing.

Let the dealership fix it and carry on.
Don’t sweat it. I think it will be just fine.

 

Free rust proofing.

 

Like mentioned above, theres plenty of fluid left, the bottom of the axle leaves about 1L in the diff. For a point of reference, I had a bad seal and drove with taht level of fluid for over 10k miles. when i replaced the seal and fluid, no damage was found. You're probably good.

Just because dealerships be dealerships and this is already an indication of their work. When you get it back give the axle a tug and make sure the clip is holding (should have been done on the install). My worry would be that a tech slams it back in and tops up the fluid and sends you on the way without inspecting the clip for retention or presence.

 

I’d maybe question the integrity of the axle seal at this point.
But you’ll know fairly quick once it is back in.

 

Low risk but good point. If the axle was drooped on the seal there could be some damage. Hopefully they clean up the area when they are done and a leak will be evident. If not bring a can of brake clean with you and hose the area down asap, a bad seal can let oil out pretty fast.

 

Have them service your front diff and inspect the seals and you should be good.

 

As said above, i wouldn't worry about the longevity of the diff as only the spiders are turning and under no load. The shaft is still in the bearing hole so that should preclude any debris getting in there on a short trip.

I'd have them pull the shaft out and provide photo evidence that the retaining clip is in fact in there and undamaged before reinstalling. If it is indeed missing, then definitely have them borescope (or open up) the diff to ensure the clip isn't sitting inside, waiting to get sucked up by the ring gear next time you use 4wd. Maybe replace the bearing/seal out of an abundance of caution since the CV joint was loose in there, but it's probably a non-issue.

But if the above turns out fine, I'm pretty confident the diff won't have any longevity issues due to this. It's just an open diff with no load on it. Even if it ran dry, it'd likely be fine. the burning oil smell was just splashes on your exhaust.