Darn It! I need help, I keep losing my front CV axles out from the Transfer Case.

Good Morning, all. I have a 2011 dual cab Taco that I use as a daily driver. It has a 4Liter V6 and an automatic tranny. I was on here about a year ago asking for advice on the make of CV axles to use to replace the original set that came with my used truck. I decided on using NAPA parts, as they were listed as being new.

I was going to use this and several other upgrades like new struts and shocks as lessons and to spend time with my grandsons. I then had the left side pull out but We never had time to start so I had our local auto shop do the shocks and struts as well as the new CV axles them for me. (we replaced both,) just to make things better known as I work to update and make this rig solid.

Within 2000 miles I lost the brand-new right-side axle, replaced that, lost the left side shortly after that. We replaced that, then the right side again about 1500 miles later, and just lost the right side again this week with an additional 3000 miles on it. I have bought new axles each time.

I have not done any rock crawling, some short stints of 4x4 wheel drive, mostly clay roads, been stuck a couple of times. The clay here is the greasiest that I have ever seen it nearly 76 years of back country living, working and travel.

At first, I thought it might be the tires that came on the truck because sometimes the tires would rub on the frame. I replaced the tires with Firestone Destination X/T 10 ply LT245/7.5R16 120/116S tires that don't rub. There is no lift on this truck, it is stock.

The axles are coming out of the transfer case and it looks to me like the robust C-Clips are pulling off but the mechanic. says not. I was am worried about such clips being in the transfer case, he says they are not.

Does anyone have any experience with such trouble on 2nd gen Tacomas? I thank you in advance for anything you can add. We only have one auto shop in our town and it is 25 miles to the next one. He and his crew work mostly on 4x4s. That is what most people drive here in NC Wyoming. He does great work for us and everyone else, except for this problem.

 

This is a new one for me on a factory height truck. Do you have photos of current cv's on the truck as well as the ones that have pulled out? Maybe they weren't seated into the front diff all the way? only thing keeping it in is the c clip

 

What exactly do you mean by "lost" a CV? The inner stub is coming out of the front differential, is that what you mean?

 

Lost as in probably damaged and in need or replacement.

Stock height and these problems lead me to believe they aren’t being installed fully where the retaining c-clip is fully engaged in its home.

 

Yes I mean that I am afraid that the c-clips pop off and the only place they could be is in the sump of the transfer case. How do we tell if the end of the axle is fully seated?

 

Mmmm you'll leak gear oil if it isn't seated. You sure the c clips were there to begin with? I mean I haven't seen a replacement come without one but ya never know. If the c clip isn't sitting in its groove it would be fairly easy to just slide the axle out.

 

The CVs go into the front diff, not the transfer case.

There should be noticeable resistance when trying to remove a properly installed CV. If it slides right out then it is not engaged fully. You should also be able to tell visually, as it will be sticking out a fair bit further than it should.

There are lots of videos on installing CVs. That may be a good resource for you

 

Im not sure thats strictly true.. The seal is in the diff housing right, so if its seated just 'enough' that may still be sealing against the CV.

But to your point, would definitely recommend some new gear oil in the front

 

I see what you did there , but yeah you're probably right

 

Axles coming out of the TC, I need to see this, maybe I have been doing it wrong this entire time. My trucks lifted and has 68K+ miles on the original CV axles with no problems.

 

Joking aside, Id think a CV coming out of the diff would result in damage. Same as a u-joint breaking. The thing is still being spun from the other side after all

Kind of why I was curious what exactly OP meant by 'loosing' a CV

 

Oh absolutely, I agree

 

I will try to post some photos this weekend. We have put new axles on each time we have lost one, I am assuming they are damaged. We usually identify the trouble when we hear clunking up front on one side or the other.

Zack. I have always assumed that the end is fiddled from banging around. I like your front bumper, did you build it?

The CV boots were going bad last winter and I had both replaced so we did not have worry about them for awhile. I am too old and bent to spend enough time under the truck to do it myself. This 4x4 is much different than those that I have worked on 30 years ago.

 

If you're hearing clunking from your front end, your CV might not be the problem. Check the play on your lower control arms and lower ball joints. If they're original, they may be due for a change. I had a clunk when going over bumps, turned out to be my LBJs but your mileage may vary.

-J

 

Napa axles have a life time warranty. If they break then Napa will replace them for free.

Need some pictures of broken axles and how yours are currently installed.

 

If these keep pulling out, try a different brand? CVJ axles, maybe? I've never had a problem with them. They're reman'd toyota axles. Try taking some measurements of the splined end that goes in the diff. Wonder if there's some minor differences in the ones you have.

 

https://www.youtube.com/watch?v=Pby128CdrLI

This was the video that made me decide to go with OEM.

Good Luck!

 

hanks guys. We had the ball joints and wishbones replaced when we had the first work done. realigned and I thought we were ready to go. I am 75 years old with a badly beat up back, so I don't get under a truck very often. It is not the getting down that is bad it is moving while down and then getting up after I am down.
This problem cost me a vacation and this years hunting trips. We are on our way to talk with the shop now.

 

The mechanic says the C clips aren't coming off. So then they are still on the old axle?
You think they are coming off.
Did you see them on the axle after removing?
I'm not understanding, either, how they're coming out unless improperly seated, bad/wrong c clips or wrong axle all together.

 

Good luck. Snap pictures for us. Worth a 1000 words...