As some of you know, I broke my front passenger's side CV on Saturday (see post). This evening Scott (JadeRunner) and Jeff (the marmot) helped me install a new re-manufactured axle. It seemed to go okay.

But when I got home, I discovered gear oil leaking out of the seal beween the axle and the ADD housing, and not a small leak at that. (It doesn't appear to actively leak when the truck is parked.)

I pulled on the shaft to confirm that the C ring was properly seated to hold the shaft in, and it wouldn't pull out, which is good. However, I could push it in a little bit, which struck me as odd.

After studying the situation more, I discovered that the re-manufactured axle appears to be mising a metal ring that is on the outside of the tripod (inner CV) of the axle I removed (and also my driver's side axle).

These are pictures of my the ring on the axle I took off:

<img src="http://www.h2net.net/~mgbrown/images/axle/1.jpg" alt=" - " />

<img src="http://www.h2net.net/~mgbrown/images/axle/2.jpg" alt=" - " />

Does anyone have any information on the purpose of this ring? Does this sound like a reasonable diagnosis of the cause of the problem?

I'm really bummed because we're going to have to do this whole thing over again. (Plus my wife is without transportation again.)

The lesson here might be to really study re-manufactured axles to make sure everything looks correct before you install them. (I'm surprised we missed this, because we were studying them pretty deliberately tonight, comparing them to a Tacoma axle Jeff had brought with him.)

<small>[ April 17, 2003, 11:43 AM: Message edited by: Aurora Sandman ]</small>

That ring is just a dust guard. When the axle is properly installed, it should sit flush with the differential housing - making it somewhat inconspicuous. It should not cause any leaks since it's purpose isn't to seal, although I would ask for a replacement axle if the one they gave you is missing it.

As for the leak... when you remove the CV axle, diff oil will start leaking out. What you're experiencing could be just some residual oil that came out during the install, that's getting flung around now. I'd keep an eye on it though.

<small>[ April 17, 2003, 09:18 AM: Message edited by: phong ]</small>

So did you end up using the Tacoma axle? What are your impressions?

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by phong:
<strong>What you're experiencing could be just some residual oil that came out during the install, that's getting flung around now. I'd keep an eye on it though.</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">So I guess I can drive it around without worrying it's going to drain too much? Well, that's good to know. Last thing I want to do is loose the fluid and wreck the gears.

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans"><strong>So did you end up using the Tacoma axle? What are your impressions?
</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">I located a 4Runner axle at a different store in town. <img border="0" title="" alt="[Smile]" src="images/icons/smile.gif" />

<small>[ April 17, 2003, 09:28 AM: Message edited by: Aurora Sandman ]</small>

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by Aurora Sandman:
<strong>So I guess I can drive it around without worrying it's going to drain too much? Well, that's good to know. Last thing I want to do is loose the fluid and wreck the gears.

I located a 4Runner axle at a different store in town. <img border="0" title="" alt="[Smile]" src="images/icons/smile.gif" /> </strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">I think you're OK in that respect. If you haven't returned your core, you might be able to transfer it over from the damaged axle. I really don't know how it's attached. Definitely get a replacement axle with it, though. It keeps dust off of the seals/bearings.

Congrats on the finding the 4Runner axle, too bad you have to do it all over again <img border="0" title="" alt="[Smile]" src="images/icons/smile.gif" />

BTW, how long did it take you guys?

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by phong:
<strong>If you haven't returned your core, you might be able to transfer it over from the damaged axle.</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Yeah, that sounds like a good possibility.

There was a small amount of clear yellowish fluid, which looked like gear lube, when we took the axle out of the ADD mechanism. We didn't know how much fluid to expect to pass through the ADD.

I think it took us an hour and half, which included a bunch of distractions. I think doing it in half of that time is very realistic for the next time. JadeRunner took several pics of the process.
Jeff

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by phong:
<strong>If you haven't returned your core, you might be able to transfer it over from the damaged axle. I really don't know how it's attached.</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">I don't know either. (Jeff might be able to check his owner's manual.) I don't see any obvious way to take it off.

The ring may be a dust cover, as you say, (which I don't doubt), but it it also prevents the axle from being pushed further into the ADD housing, (which, in its abscence, I am able to do). On the dirver's side, if I push or pull the tripod, it really doesn't move very much. I believe the movement on the passenger's side is much greater because that ring isn't there.

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by phong:
<strong>So did you end up using the Tacoma axle? What are your impressions?</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">As to my impressions, I think we all agreed it was pretty easy. Getting the axle back in was difficult (we placed a crowbar up against the tripod housing and hit it with a sledgehammer).

I don't think I would want to do the swap on a trail unless I really needed to. If I had the option of just going home (or back to camp) in 2WD, I'd probably choose that. But in a pinch, it's doable. You'd probably have to have some tools, though -- including a jack stand or two, a crowbar, and a sledgehammer, a torque wrench, 35mm socket, etc. -- and preferably a level spot on hard ground.

Received from Steve Schaefer:

d00ds-

I guess I forgot to tell you that you should remove the dust seal from the
outer edge of the outer CV and the inner seal on the inner CV and reuse the
ones form your original axle. They do not come with re-builds.

I ordered new ones from the dealer for my spare and the ORS kit come with
new ones as well.

Homo Burrito

Okay, I just took the dust cover off prying it with a screwdriver. Easy enough. So I know to re-install it with the dust cover.

Has anyone else experienced the leaking gear oil when driving right after the install? Is it likley normal and will likely go away?

<small>[ April 17, 2003, 11:52 AM: Message edited by: Aurora Sandman ]</small>