Removing Broken Inner CV Axle Shaft

[Vermejo]

When the CV breaks at the inner axle shaft extraction or teardown are the two options. The broken shaft in inaccessible by simple measures.

-Jack and support front end safely

-Remove tire, damaged CV and shock assembly (Plenty of write-ups on CV removal)

-Mark and indent center of broken shaft

-Wedge paper into the bottom of the housing to catch metal shavings

-Make sure your drill fits into the tight space at a straight angle. If the drill does not fit removal of the LCA is required. The DeWalt I used was big and had to be operated upside-down to get a straight line on the shaft

-Use a 5/16 cobalt/tungsten carbide tip bit for drilling. Drill a pilot indention with 4WD disengaged to spin the shaft and center the hole more easily

-Engage 4WD and front locker and drill approximately ½ inch deep

-Start the 3/8 tap by hand and continue with a wrench. Back the tap out every so often to clean the threads and clear metal particles, wasted gear oil will assist the tap

-Thread the 3/8 bolt and remove the shaft with a slide hammer. The Harbor Freight model I used was 3/8 and threaded directly into the shaft. Otherwise use a 3/8 bolt and slide hammer jaws. (in the tools pic note the shaft piece at the end of the slide hammer)

-Thoroughly clean the housing to remove any shavings/debris

-Change the diff fluid and check the drain plug for metal after a few miles if needed

http://i43.photobucket.com/albums/e352/BearJake/DSC_0321.jpg

http://i43.photobucket.com/albums/e352/BearJake/DSC_0322.jpg

http://i43.photobucket.com/albums/e352/BearJake/DSC_0329.jpg

http://i43.photobucket.com/albums/e352/BearJake/DSC_0330.jpg

http://i43.photobucket.com/albums/e352/BearJake/DSC_0331.jpg

http://i43.photobucket.com/albums/e352/BearJake/DSC_0332.jpg

[MTL_4runner]

Good job on that fix. :thumbup:
Not sure how else you'd get that out besides the way you did it.

[YotaFun]

Awesome write up.
wonder if ones without a front locker could do this...

[Seanz0rz]

wonder if ones without a front locker could do this...


just leave the other tire on the ground or wedge it or something.

[4Runner202020]

I'm glad I could help you with this man. Its a weird break and I guess my instuctions we're good enough. LOL thank for the right up to!!

[MTL_4runner]

wonder if ones without a front locker could do this...


just leave the other tire on the ground or wedge it or something.


X2

The answer is yes, absolutely.

[Vermejo]

Thanks for the info, you along with Sonoran Steve and Jon (111db) had some good input that needed to be there for the next person that breaks a shaft in this form. This would make a tough trail fix to bother hauling the tools, but it is a good DIY. The Harbor Freight slide hammer fits into the space perfectly and cost $16.



I'm glad I could help you with this man. Its a weird break and I guess my instuctions we're good enough. LOL thank for the right up to!!

[20005spd]

this happened to a taco last year i was wheeling with. he put the stub shaft back in the hub, and put a latex glove around where the diff was open. when he went home he did the same thing u did and it worked easy.

[Vermejo]

http://i43.photobucket.com/albums/e352/BearJake/DSC_0317.jpg

We added armor over plastic-wrap

[04 Rocko Taco]

You wouldnt want to do it as a trail fix, (but I dont think your way is going to happen on the trail either)but it is fixable other ways, teardown of the front diff, no it isnt fun, but yes, its possible. I'll post the goodies up in a minute.

[04 Rocko Taco]

This is the other option I was mentioning, it happend at Tellico last weekend for the Southeast TTORA Toyota Takeover.


Its on the drivers side.
Here is the broken shaft
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1021081646.jpg
Sorry for the bad pics I was in a hurry the shop was closing and I had to get a ride home. But I need to know how to get the gear off in the center of the pic. The FSM says to use a puller and I guess I just want to make sure before I go jerking around on stuff.
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1021081646a.jpg


Finally got the little thing out of there.
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1022081338.jpg
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1022081337a.jpg
Missing something.
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1022081337.jpg
http://i45.photobucket.com/albums/f86/98taco4x/Misc%20pics/1022081336.jpg

Once I saw how to get the intermediate shaft out it didn't take me 2 minutes to get everything apart. Thanks 99flowtaco. Hell getting the Budbuilt off is about the hardest part.

[4Runner202020]

ya before i did i drilled it and stuff we tried droppin the diff but blake and i couldn't get it out for the life of us... so we came up with the drilling it idea. lol looks like our way took less time and skill. no way i would have wanted to get into that mess...

bobby