As long as the boot isn't blown and the grease is still in there, I've never heard of an OE axle developing play under normal circumstances.

If you don't want to spend the money on CVJ, the next best thing is to get an OE axle from the junkyard and rebuilding it with the OE boot kit. Thermoplastic is the OE material and is far superior to neoprene which is what all the other rebuild kits use.

With a 3" lift, a diff drop is also mandatory to straighten out the angle IMO. No CV boot is going to last more than a couple years with those extreme angles. I've been changing out my CV boot every 1-2 years thinking that different brands would be better, but they are all the same. Finally caved in and did a diff drop which is what I should've done from the beginning.

What would the correct OEM part number be for the following:

2002 4Runner converted to manual hubs?

SonoranSteel did a write-up and included the part numbers:
Technical Articles : Sonoran Steel Fabrication LLC, Toyota Truck Parts

I did see that article previously, I just can't find any detailed information about what it actually takes to make it happen. I have searched and searched but I just can't find anything

I suspect it'll take some narrowing work to clear things. Modifying of diff bracket arms to sit correctly. Or build custom bracket arms. Custom CVs from someone like RCV to go from 8inch to our ifs hubs. Stock CVs may work depending on how long or short you need em. If need longer Tundra CVs maybe applicable to the situation. Lastly swapping front driveshaft or lengthening/shortening for optimal angles once the front axle is in place.

Seems like a bit of work for cool points when someone stops you at the mall to ask about your rig. I'd need to murder a few 7.5 diffs first or be looking to build a rig to race KOH personally to make me consider it doing all that work.

Looks like I was pretty close based on this...

Front diff upgrade time. - Toyota 4Runner Forum - Largest 4Runner Forum

anybody have a part number for the NAPA maxdrives? their current online listing does not have any indication... hopefully they didnt do away with that product line.

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Not entirely sure about Napa MaxDrive, but I just had these 1258's installed. They're Napa Heavy Duty CV's. So far they've performed excellent (knock on wood) although I'm only DD'ing my rig these days, and the occasional drive on sand when at the beach.

Napa Heavy Duty Axles

I’m pretty sure the 1258s are exactly the same as the TrakMotive TO8043ET Extended Articulation CV Axles that O’Reilly sells?

If so, then they’ve been great for me. So far about 6k miles with some moderate wheeling as well.

I honestly had no idea about that. That’s good to hear you’ve had good results with them so far. Like I said, I only DD my rig nowadays so my only concern is the boot tearing. I drove around for a few years with ripped boots and thankfully I along with the truck was okay. But I’m very pleased with how they Napa ones turned out. Have you had any boot rippage or any rusting so far?