We put the flange\spacers on from the old axle to both sides of the new axle. Installed in all. Took a test drive and it leaks again. After discussing this with someone in my club who works for Toyota USA we discovered the following.

The seal in the diff housing (pictured) has been pushed in too far and damaged. I assume that when we hammered the axle in the first time we hammered it a little too far. Which pushed this seal in too far. Thus knocking it out of it's "seat" and damaging it.
<img src="http://home.earthlink.net/~scttntna/_uimages/inneraxle.jpg" alt=" - " />

Mike will be getting a new one (20.00) from Toyota on Monday and we will put it. We don't have the proper Toyota tool to get put the seal in. So we will have to be careful. It is supposed to go in the housing just under 1/4 inch. My friend gave me Toyota instructions on a pdf on how to install it properly. I "print screened" a page and posted it here.
Install instructions

</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"> where is the best place to source a reman CV?
</font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Jeff referred Mike to another place here in Denver. I forgot the name of the place. Maybe Jeff with chime in. But they had the correct 4Runner axle and it was only 175.00 before core return. The best price going I think.

<small>[ April 19, 2003, 09:48 PM: Message edited by: JadeRunner ]</small>

That doesn't sound easy at all to get that new oil seal in place in the ADD housing. That's not encouraging.

Mike got his axle from Import Parts Warehouse. I had learned that some dealerships get some parts from there when they can't order them from the manufacturer.

Import Parts Warehouse
501 Kalamath
Denver Colorado
(303) 825-2000

<small>[ April 19, 2003, 09:58 PM: Message edited by: Jeff the marmot ]</small>

Jeff,
I don't imagine you have a seal puller?

Also if we could fabricate something round and hollow about the size of that seal. We could tap it in easier.

I had the same issue with a leaking damaged seal. In addtion, the snap ring didn't retain the tulip and pulled out while driving. It sure leaked then. <img border="0" title="" alt="[Roll Eyes]" src="images/icons/rolleyes.gif" />

Lars,
Did you install the new oil seal yourself? Did you use any special tools.

I'm thought we could get a seal puller from AutoZone. But, they looked it up and told me they don't have one for that application in the proper size. And I'm thinking of getting a piece of PCV close to the correct size to knock it in with.

Any other ideas welcomed.

Best sealer tapper I have seen with a PVC piece for front axle inner oil seals. Sounds like you are on the right track with that.

Good heads up on CV's, hopefully I won't have to stop in there this summer.

As if you all needed any more encouragement, this sounds like a big help to all who will come afterwards, I tip my hat.

</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 larsdennert:
<strong>I had the same issue with a leaking damaged seal. In addtion, the snap ring didn't retain the tulip and pulled out while driving. It sure leaked then. <img border="0" title="" alt="[Roll Eyes]" src="images/icons/rolleyes.gif" /> </strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Did you put the new seal in yourself? If so, do you have any insight to share in regard to how to go about taking the old one out and putting the new one in?

Also, were you referring above to the snap ring on the shaft? Do you know what caused it to fail? (Any "lessons learned" you could share on this process would be much appreciated.)

</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 JadeRunner:
<strong>Jeff, I don't imagine you have a seal puller?</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Nope.

Claw hammer. <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" />

I guess I answered Mike in email.