Removing CV axle and changing CV boots on a 86-95 IFS toyotas.

Note: This will not work for 96+ IFS.

To remove the axle

1. Remove the hub/ADD flange, the bolt in the end of the axle, and the C-clip
2. Remove upper bumpstop and disconnect the sway bar and shock.
3. Loosen the 6 nuts holding the CV axle to the diff side of the axle.
4. POUND or press out AT LEAST 2 OF THE STUDS. --The single most important step. Click here for idea source.
5. Jack up the truck so that the suspension extends all the way.
6. CV axle should slide right out.
6a. Some people have success with the above method and some don't. If you don't, then the next step would be to unbolt the lower ball joint to get the axle to clear.

(1) Toyota CV boot kit 04438-35022 $23.42 each. One kit comes with two boots, clamps and the special greases. Price quoted in 2003.

http://www.robinhood4x4.com/albums/misc/axle.jpg

1. Undo the clamps.
2. Remove inner housing by removing boot.
3. Mark tripod joint and axle so that the tripod joint goes back on in the same splines. (Also, so that you don't flip the tripod joint around the wrong way).

http://www.robinhood4x4.com/albums/m...arks.sized.jpg

4. Remove C-clip and remove tripod joint.
5. Old boots will slide off now.
6. It is not recommended that the outer CV joint be rebuilt. I just wiped as much of the old grease off as I could.
7. Tape end of splines so that the boots aren't cut.
8. Slide on new boots and clamps but do not clamp yet.
9. Slide on tripod joint, making sure reference marks line up.
10. Install NEW snap ring that retains tripod joint on axle shaft. Apply 6.2-6.6 ounces of Black colored grease supplied with overhaul kit to outer joint and boot.
11. Pack 9.6-9.9 ounces of Brown colored grease supplied with overhaul kit into inner joint and inner housing. Install inner housing on axle shaft so reference marks are aligned.
12. Install boot on inner housing and outer joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length of 15.508-15.902in (for 1995 4runner, sorry, that's all I have, probably the same for all 2nd gens). Measure axle shaft length between inner joint flange
and outer joint flange.

http://www.robinhood4x4.com/albums/misc/axle_length.jpg

13. Tighten boot clamps.
14. Install axle.

I received an email from navyredneck:

Quote:

the bolt size to replace the studs is M12 by 1.25mm by 35mm which allows you to reuse the nuts

You'll need two per side and this really is the key for making the cv axle replacement easier (cut my time in half).

Oh, and I had to use a 3 foot length of steel rod and sledge hammer from the local hardware store to knock mine out after it bent an 8" C-clamp.