3rd Gen CV Axles new but damaged?

[dirteater4]

Hi 4runner folks! First off, love the site and the people that are a part of it. Just replaced both of my CV axles by following the link above. It took me about 50 minutes for the drivers side last weekend and about 40 minutes on the passenger side a couple of days ago. What Im running into: When I have 4 high engaged, and turn the wheel slightly right, I have a popping sound (like a bad knuckle or joint). Turning left there isnt a noise. Both are brand new (not a re-furb) and from NAPA. Could the axle have been bad when I bought it? Install went flawless, snap rings in place, and no leaks. Any ideas? Thanks in advance.

 

[AZ4Running]

I woukd start by replacing the axle again.

 

[LittleCaesar]

With it being a PITA, switch the CV axles or put an old one in back in starting with the driver's side.

I'd bet it is something else with the noise being manifested due to the new axles.

 

[JWaldz]

Probably unrelated but when was the last time you checked or changed the fluid in the front diff?

 

[EatonKyleH]

I've had many axles come in brand new but bad/defective... mainly from aftermarkets such as NAPA. Several were assembled and shipped with no grease in the boots at all. Others just poor tolerances (could feel extreme resistance trying to swivel the joint by hand)

Of course check your front diff fluid and front end before tearing back apart but it's definitely far from unheard of to answer your specific question.

 

[dirteater4]

Probably unrelated but when was the last time you checked or changed the fluid in the front diff?

Thanks for the replies. I changed the fluid 2 months ago. Everything inside was beautiful, including the fluid color. Ive got the "un-leaky" factory axle I took off the drivers side that I can switch out to check against the new one. What else could have manifested because of the new axles? Thanks for the response Eaton. I went with NAPA because there were numerous good reviews on t4r. What was your experience?

 

[EatonKyleH]

Thanks for the replies. I changed the fluid 2 months ago. Everything inside was beautiful, including the fluid color. Ive got the "un-leaky" factory axle I took off the drivers side that I can switch out to check against the new one. What else could have manifested because of the new axles? Thanks for the response Eaton. I went with NAPA because there were numerous good reviews on t4r. What was your experience?

Typically they are fine and trouble free. It's just in the several hundred CV axles I've done at work I've had a handful.... maybe 6-7 axles that came in defective.

 

[dirteater4]

Typically they are fine and trouble free. It's just in the several hundred CV axles I've done at work I've had a handful.... maybe 6-7 axles that came in defective.

Out of hundreds, I guess 6 or 7 isn't bad. I've decided to swap the axle out this weekend. I will keep you guys posted. Thanks again for the feedback!

 

[dirteater4]

Typically they are fine and trouble free. It's just in the several hundred CV axles I've done at work I've had a handful.... maybe 6-7 axles that came in defective.

OK, so the bad news is the sound remains with the un-leaky factory axle reinstalled. What could I be missing? If it was the hub, it would do it 2wd as well. If it was the transfer gear box, wouldn't it make the noise no matter what (driving straight, turning left, turning right)? Anyone else experienced anything like this?

 

[Sierra946]

Did you reconnect the sway bar end links? How old are your lower ball joints? Did you retorque the axle nut to specs so it's seated all the way in?

 

[dirteater4]

Did you reconnect the sway bar end links? How old are your lower ball joints? Did you retorque the axle nut to specs so it's seated all the way in?

Yes, 1200 miles, & yes.

 

[dirteater4]

Bump. It only does it in 4wd.

 

[dirteater4]

So Ive also identified the popping is also not as severe or loud with slight turns and lower speed. The further I turn it, the louder it gets. I also looked the gap of the cv, it has almost half an inch of play at the differential. The dust shield is seated properly. Help!

 

[dirteater4]

Did you reconnect the sway bar end links? How old are your lower ball joints? Did you retorque the axle nut to specs so it's seated all the way in?

Just wanted to give an update on this thread before I start a new one. I figured out the problem! I omitted in my first post (because I forgot) that I installed the diff drop kit when changing out my passenger side axle. When installing the diff drop kit, I followed the directions and posts that I read on this forum. Everyone suggested putting a jack under the diff to catch the weight after removing the bolts. I ended up lowering the jack and had to pull down on the diff to get the spacers installed. I didn't think anything about it....until last night. I uninstalled the diff drop kit, took the truck for a spin, problem gone! Still have no idea what could have been the source of the popping.