CV end snap ring fitment issues:
Now for the fun part. As mentioned previously I did a manual hub conversion on my 4Runner. It is still equipped with ADD.
There’s a stub shaft that installs into the passenger side of the differential. It is part of the ADD tube. The passenger side CV plug into the ADD tube — there was no issue with all this. Everything fit as it should.
However, I soon found out that the stock Tacoma CVs did not fit into the driver’s side of the differential all the way. It would go in 90% of the way but the snag ring would not engage. Without the snap ring engaged the CV can be pulled right back out and does not engage with the oil seal properly.
It was a puzzle to determine the offending feature preventing the CV end from plugging into the diff but it turned out to be that the splines were not long enough. The CV splines would run out just before the snap ring was able to get beyond the internal splines of the side gear where there is clearance for the snap ring to “snap” out and lock.
Interestingly enough ECGS had tested and confirmed fitment of a CV for me to help me confirm the TrueTrac would work for my application. But it turned out they were using a normal ADD CV — it had never occurred to ECGS or myself that the CV ends could be different.
In troubleshooting the issue I got access to three CV shafts to experiment with: 1) a stock Tacoma non-ADD 2) stock 4Runner ADD and 3) an aftermarket Cardone CV for non-ADD applications.
Here are a series of pictures showing the inner CV ends and how they fit into the driver’s side of the TT-equipped differential.
Stock non-ADD Tacoma manual hub CV:
As you can see, the dust flange on the CV end is quite far from the oil seal. At this point the snap ring is also not engaging.
Stock ADD 4Runner CV:
At this point the snap ring has just engaged. The dust flange still has a small gap from the seal but we could always cheat the seal outboard a bit to compensate. The splines are clearly longer on the 4Runner CV than the Tacoma CV. Why? Who knows.
Aftermarket Cardone CV:
Here you can see that the aftermarket CV actually fit very well. Its splines are longer allowing the CV to install deeper. The dust seal is properly located with respect to the seal.
One solution would have been to run this aftermarket CV on the driver’s side and call it a day. Unfortunately, as many of you know, aftermarket CVs are quite inferior to stock ones with respect to strength. I have personally had two wheeling trips prematurely interrupted by a busted aftermarket CV and I’d rather not repeat it.
Note: It had occurred to me that perhaps the stock 4Runner inner CV end could be “grafted” onto the stock Tacoma CV. This is not possible — the inner splines are different sizes and the tulip joints are also not interchangeable. The 4Runner stuff is all just a little bit bigger than the Tacoma stuff. This would have been a nice solution but alas.