1992 4Runner...IFS intact. PO converted drive flanges to Warn Hubs <img src="/forums/images/graemlins/barf.gif" alt="" />. Long story short...took apart my front end to do the bearings and swap out CV joint. Noticed that the previous owners lack of maintenance ran deeper than thought (admittedly my saying screw it and wheeling as is did not help). Everything was rusted.
Warn hubs were improperly installed and most of the studs were jacked. Plus these things don't use cone washers?!?!? That puts all the load of moving the truck on two itty bitty pins. Either way... of the two pins on either axles hub, one is broken on each. I have factory Toyota replacements and they are press in. The pins are broken below the surface of the hub. Anyone ever dealt with this before or know absolutely how o get them out. No luck so far with EZ outs, drill bits, reverse bits, or liquid wrench. I'm about to pull out the 30-06 and "quick drill" them out to 10mm!
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Those things are a real bummer to drill out. Most of the time when you get them drilled out the holes are to big and the new pins do not fit tight. I would see if you can find some different hubs and get some Aisin hubs.

A good source for used parts here in California is Dave'z, I know that he has them. If you cannot find them up there give him a call.

http://www.davezoffroadperformance.com/

Are those really what drives the wheel from the hub?

They help along with the six studs. I have never met a Warn hub on a Toyota that I liked. Them seem to loosen, start moving and break studs and pins. Why, lack of cone washers.

/quote]They help along with the six studs. I have never met a Warn hub on a Toyota that I liked. Them seem to loosen, start moving and break studs and pins. Why, lack of cone washers. [/quote]

EXACTLY!!! These pins are a PITA! I dunno what type of steel they are made of but we figured out they were just killing the bits today. I'm going to pick up a carbide drill bit and try that sucker out. Anynbody know what grade of stell the factory ones are? The 30-06 comes next. Anyways. I figured out a way to beef up the warn hubs at the bolt on point. I'm going to counterbore the stud holes to accept cone washers (They may be a pain but not as much of a pain as broken pins) or find a sleeve that will fit tightly around my new bolts and bore the mount holes on the hubs to barely meet the OD of the sleeve. In theory this should make the mounts stroner than the OEM hubs. drive gear will still be weak though. I'm using 12.9 alloy (double the strength of a grade 8.8 which I think the OEM units are) bolts to go where the broken OEM studs were. I'm not aware of anything tougher than those except maybe the ARP units but thats probably only by a narrow margin. Yay or nay?

leave the broken one alone.
turn lock out and drill two new holes.
drive in new pins.