Outer CV Excess Plunge

After installing the 3.5" longer axles on Jen's truck, with her stock inner and outer CVs, we went on a trail ride. I think she might have turned on pavement by accident, because we started hearing a pop when she was turning at full lock on dirt and accelerating.

I got out and noticed the passenger side outboard CV was popping when she was turned at full lock and moving forward. When going straight, nothing was wrong. I grabbed the CV and noticed I could plunge the outboard CV quite a bit. The drivers side outboard CV doesnt plunge at all, which is normal (only inner CV should plunge).

When we got home, I peeled back the boot to see what was plunging. The shaft was not plunging in the star, so I know it's not the C-clip that was broken. What was plunging was the whole CV cage assembly with the ball bearing plunging in and out of the CV cup, as if the whole thing would come out. What could have caused this malfunction? Could the CV cup have become deformed when we turned on pavement?

 

did you break the cage maybe?

 

When i peeled the boot back and checked, the cage seemed fine and intact.

 

hmm idk then.

i have a couple tundra outers that i took off mine to make axles for my truck.
they came off a 2001 tundra ADD if that will work for your application.

 

was it popping in/out or side/side?

 

the shaft, race, bearings, and cage, together as a whole, was popping out of the Outer CV cup at full turning lock, while moving. Not side to side, forward and backwardds towards and away from the diff/truck.

 

im willing to bet something got worn down in the CV maybe so the tolerances are off then making it able to pop in and out?

did you see my fist post about the 2001 tundra ADD outers?

 

not sure if it will work. worst case i go to the junk yard and buy a tacoma CV. whats the spline count on your tundra outers?

 

are you wondering the spline count on the shaft on the CV joint, or the spline count inside of the CV that the axle shaft goes into?

 

The CV stub that goes through the wheel hub.

 

i will count when i get home and get back to you.