Thanks, that makes sense. I will be polite to the service writer but let him know of my frustration at having to bring it back for a poor installation.

So can they simply be crimped more to meet the proper specs or are new clamps required now? I don't want them half-assing it again.

Should be able to crimp the clamp that is on there now, but it is trivial to install a new one - they can be opened, the axle doesn't have to come off.

Yes, the clamps can be re-crimped tighter, based on my personal experience of using a hand tool to tighten this style of clamp. Note, I added more information and two additional images to my original post, showing clearances when the clamps are properly tightened. Show the service writer your picture, the three images I posted and note the different clearances for the larger and smaller clamps. It should be obvious to the service writer that the clamps are not properly crimped. Ask them to check crimp on all four clamps.

Thanks again for the info, good to know. Should there be any concern about the loss of grease (the amount) or anything else assuming they fix the clamps and the leak?

I took a pic of the passenger side. That crimp looks pretty weak, too.

Oof those crimps look piss poor. The person who did those used the more readily available CV Crimp tool that most mechanics probably have in their box, looks something like this:



Those pliers are a cheaper than the SST and easier to get if you want to crimp them down yourself. Usually if you ate your Wheaties you can get them pretty tight just by hand squeezing them, but that's why they have the 1/2" socket holes in them, most guys just double them up with breaker bars and give them a good squeeze. Just be conscious of keeping the pliers perpendicular on both the X & Y axis when doing that, I have seen them get twisted and result in a leaking clamp before (done it myself once or twice, which was why I was so ecstatic when we got our fancy crimper I mentioned.)

Post Note-

I wouldn't be worried about that small amount of grease that's come out so far, there's plenty inside the axle. I would say either bring it back to the dealer and point it out to them, since they should take care of their crimp job not being good. Or crimp and clean the axles yourself if you feel comfortable doing it.

The amount of grease lost as shown in the pictures wouldn't concern me if the technician used all of the amount supplied with the boot kit. I suggest minimal driving until it's fixed. The dealer will ultimately decide if they want to repack the grease. I've installed boots on three vehicles and found the amount of grease supplied with the kit to be more than adequate. You lost "globs" of grease when you first noticed the problem and the joint wasn't noisy or clicking. I'm assuming technician carefully inspected CV joints for damage before deciding new boots would be sufficient. Keep this repair receipt in a safe place. The chances of developing a problem later as a result of this leak are very remote.

Thanks again for the info. It's still covered by warranty (I even have an extended warranty) so I am going to force the dealer to make it right. I'd make them fix this job though even if I had paid out of pocket.

In an earlier post, I wrote that a service advisor should realize the clamps are not properly crimped if you show him your pictures. However, now that I think about it, perhaps a few may understand and most might not. I suggesting you tell the service writer the new boots are leaking and ask if you may speak with the shop manager (foreman). Take a printout of the 3 pictures and clearance specs that I posted earlier so you can show it to the shop manager along with your photos of the improperly crimped clamps. Hopefully, this will compel the shop manager or an experienced technician to inspect the second repair before they return the vehicle to you.

OP sorry to hear about your mishap...on your second trip to the dealer they better be apologetic for the inconvenience of not inspecting their own work and making you take time out of your schedule for a return visit. If not complain to Toyota Corporate.

Looks like poor CV boot strap crimps are a thing now, same issue, I'd rather not buy $250 tool... will Lisle 30800 CV Boot Clamp Pliers, work to crimp it better?

At least the new boot isn't torn, so that's a plus.

I have the Lisle boot clamp pliers, and yet haven't had a need to use it on the 4Runner. If you can reach the clamp with the tool perpendicular to the boot clamp, then it would be fine to use. If the boot is not leaking, I would tighten the clamp a little bit more and check it once a month for 3 months.

yes they did not properly crimp the strap ..

go to the dealership and take pictures on the new vehicles on the lot with the boot strap new and on yours .. not correct....

I would genuinely laugh my ass off if it turns out that the factory wasn't crimping the boots to their own specifications as well.

Shit, now I want to check all the ones on the lot when it gets slow for shit's and giggles.

Toyota undoubtedly has a supplier for CV axles. Probably a Chinese manufacturer who uses women to crimp the clamps. Diversity matters!

My originals went a little over a year before they leaked. Seems odd that they would just suddenly start leaking like they did.