CV Axle Reboot, Grease, Clamps, Tips

[88Center]

Rebooting my CV Axles and ran into a problem, maybe.

The 5th gen reboot kits don't come with enough grease, when compared to the amount specified in the repair manual. If you want to follow Toyota specs, you'll need to order a separate tube of grease.

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OEM Reboot kit: 04427-60133

Grease 1: 90999-94250 (Raremax SLF)

Tube 1: 128g / 4.51 oz
Tube 2: 128g / 4.51 oz
Total: 256g / 9.02 oz

SLF for outer boot.

Grease 2: 90999-94187 (Raremax UBZ)

Tube 3: 170g / 5.99 oz

UBZ for inner boot.

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CV Axle Grease Amounts

Comparing the amount of grease included in the 5th Gen reboot kit to the amount of grease specified in the 4th Gen repair manual, there is not enough UBZ grease included in the kit. I need an additional 2.2 (62g) to 2.6 oz (73g) of UBZ grease per cv axle.

Outboard Joint Boot
Grease capacity:
260 to 270 g (9.2 to 9.5 oz.)

Inboard Joint Boot
Grease capacity:
231 to 241 g (8.1 to 8.5 oz.)

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Called the parts department at largest Toyota dealership in the world, Longo Toyota. That's where I got the kit from. Parts guy said the reboot comes with exactly the amount you need. I told him ok, so the engineers got it wrong on the Repair Manual? He said "It's not like you need to fill the entire boot with grease. It should be good."

I called back and talked with a different guy. He was much more helpful and brought in a tech. The tech said the kit does come with the correct amount of grease, and that I'm supposed to use the entire tube for the inner, and both tubes for the outer.

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Had to do a deep dive because these tubes are really hard to find, unless you order an entire reboot kit. Also complicating things is the tubes of grease come in many different sizes, all with unique part numbers. Further complicating things is Toyota does not specify on their website whether a tube of grease is SLF, UBZ, or LF-G (KAI)

Here are the ones I could find, with Toyota part numbers, grease type, and amounts. These come in toothpaste-style tubes.

Also note, the last five digits of the Toyota part number match the Raremax part number.

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Raremax UBZ (Dark)

• 90999-94150 (90g) (replaces: 90999-94028)
• 90999-94115 (130g) (replaces: 90999-94123)
• 90999-94187 (170g)
• 90999-94189 (180g)
• 90999-94214 (260g)
• 90999-94167 (?)
• 90999-94190 (?)
• 90999-94191 (?)
  

Raremax SLF (Tan / Ocre)

• 90999-94202 (50g)
• 90999-94250 (128g)
• 90999-94205 (190g)
• 90999-94161 (232g)
• 90999-94154 (?)
• 90999-94166 (?)
• 90999-94221 (?)
• 90999-94318 (?)

Raremax LF-G (KAI) (color?)

• 90999-34316 (150g)
• 90999-34319 (275g)

Found some more but could not ID grease type or amount

• 90999-94123
• 90999-94219

I found a few greases in stock at Longo Toyota in LA, but they can't ship due to hazardous material. Oddly, they can ship an entire boot kit, which comes with the same greases. Ffs.

 

[88Center]

Which Grease Goes Where?

I did mine this way. Not sure it makes a difference. Toyota has never specified where each grease goes. Half do it one way, and other half do it the other way.

Inner = UBZ (dark)
Outer = SLF (tan)

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Car Care Nut - Most respected Toyota mechanic on the web

Inner = Dark
Outer = Tan

https://youtu.be/YH5Cf7uJV5Y?si=ZpVxIi_kUA2MbW6h&t=1048

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Tech at Dealership I talked with...

Inner = Dark
Outer = Tan

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Toyota Tech School

Inner = Tan
Outer = Dark

https://youtu.be/xuxXjTZ7Nms?si=UEqON8TR8O7JGMmA&t=343

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According to another post, reason for the different greases is the different bearings in the joints have different shear values, and require different greases. No idea if true.

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Kyodo Yushi Co., a Japanese manufacturer seems to be the main supplier for Toyota grease. They make "Raremax" brand grease.

Grease | Product | Kyodo Yushi Co., Ltd.

 

[88Center]

CV Axle Clamps

04427-60133 | OEM 5th Gen Boot Kit, comes with four clamps, two boots, two clips, and grease.

• 42345-60280 | AA A840C Clamp (outer boot, large)
• 42345-60170 | Oetiker 99 Clamp (inner boot, large)
• 42345-60160 | Oetiker 37 Clamp (outer boot, small)
• 42345-60160 | Oetiker 37 Clamp (inner boot, small)

04427-60142 | OEM 4th Gen Boot Kit, comes with four clamps, two boots, two clips, and grease.

• 42345-16070 Clamp (outer boot, large)
• 42345-60190 Clamp (inner boot, large)
• 42345-60110 Clamp (outer boot, small)
• 42345-60110 Clamp (inner boot, small)

The following boot clamp is shown as being compatible with 2003-2024 4Runners.

• 42345-60280 (outer large)

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04437-60042 | OEM 4th Gen Boot Kit, comes with the inner boot, two clamps, two clips, and grease for inner boot.

43460-69255 | OEM 4th Gen Shaft Set, Outboard Joint, comes with outer boot, two clamps, one clip, and one shaft with cv joint.

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Clamp Size Problem

Largest OEM clamp 42345-60280 (stamped A804C) that came with the boot kit is too short for the outer boot. Simple bend-over clamp and it snapped on install.

Clamp from 5th gen reboot kit: AA A840C
Clamp from my vehicle: AJ A840B

According to FJ forum, "Large clamp on the outer boot will something like "AA A840B", which means it is a 108.4 dia clamp, plus lot number. The clamp on the inner boot will have something like: "E1209AA", which means that one is a 102.9 dia clamp, plus line number, lot number, etc."

How to tell original cv axles? | Toyota FJ Cruiser Forum

If the information above is true, not sure why the 5th gen reboot clamp snapped but it definitely seems a tad too short.

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This guy broke the same clamp.

CV clamp confusion 1 broken. 04427-60142 kit

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This guy also broke a clamp while installing.

CV Boot Clamp Issues | IH8MUD.com Forum | Toyota, Lexus & Off-Road Community Discussions

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Clamp Problem Fix

Bought 2 separate clamps to replace the OEM "A840C" clamps which come with the boot kits. These are specifically designed for CV applications and from same company that makes the other OEM boot clamps for Toyota.

Width: 3/8"
Size: 4-3/16 to 4-1/2in (106.0-114.0mm)

Oetiker Adjustable Rubber CVJ Boot Clamps, 304SS - Durable Ear Hose Clamps

Oetiker 3/8" Adjustable Rubber CVJ Boot Clamps 304SS | Ear Hose Clamps
– HCL Clamping USA

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Oetiker Clamps

Oetiker makes a wide variety of clamps and they are very robust and trusted by many manufacturers, including Toyota.

Oetiker Camps

 

[88Center]

If you vehicle is more than 10 yrs old, you're probably going to need to replace some other parts when you reboot your CV axles.

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CV Axle Associated Parts for 4th Gen 4Runner

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OEM Type T Oil Seal / Output Shaft Seal

90311-47027 (Left)
(replaces: 90311-47012, 90311-47020)
Fits 1996 to 2024

90311-47013 (Right)
(replaces: 90311-47010, 90311-T0016)
Fits 1996 to 2013

90311-47026 (Right)
(replaces: 90311-47021
Fits 2014 to 2024

Before you do anything, take ample photos of these seals, as they are installed. Take careful note of the depth they are installed. It's possible to install these to far into the housing, and then you'll have a leak of differential fluid. They can be tough to remove, so be careful not to scratch up your differential housing.

Take your time putting the new seals in! No need to buy an expensive seal driver kit. Instead, get 2" PVC coupler from hardware store to drive them into place. It fits perfectly over the seal. Tap, tap, tap, check depth. Tap, tap, tap, check depth. Do this as long as it takes. I can't emphasize enough to be careful when installing these.

The seals listed above are sometimes called Differential Carrier Front Seal, Oil Seal, Drive Shaft Seal, Type T Oil Seal, Output Shaft Seal.

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OEM Type D Oil Seal

90316-72001
(replaces: 90316-A0001)
Fits 2004 to 2024

These are inserted into the wheel hub, from the inside. The seal listed above is not left or right specific. If you are replacing both CV axles, you might need to replace these. You'll need two of these.

Pro tip, place them in by hand, being sure to push the part of the seal next to ABS sensor in first. That will keep you from having to rubber mallet around the sensor, which is also guarded by some parts. Use a rubber mallet to seat the rest of the seal. If you have some rust on the inside of the wheel hub, use some light sander paper to knock it off. This will help the seal seat more easily and you get a better seal.

The seal listed above are sometimes Oil Seal, Wheel Bearing Inner Seal, Knuckle Seal, Knuckle Dust Shield, Knuckle Oil Seal, Seal Type D Oil.

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OEM Flange Nut Styles

Old style flange nut: 90178-28002
New style flange nut: 90177-A0023

Castle cover: 43525-35010
Cotter pin: 95381-04045

If you keep your existing OEM 4th gen CV axles and rebuild, you will need to use the older style flange nut (90178-28002), castle cover (43525-35010), and cotter pin (95381-04045). Some mechanics suggest replacing the cotter pin whenever you replace the CV axle, since it is a critical safety component.

If you install new OEM 5th gen CV axles, you will need to use the newer one-time-use flange nut (90177-A0023), which is staked in place and does not use a flange nut cover or cotter pin.

The difference between 4th gen and newer 5th gen CV axles can be identified by looking at the threaded end. The newer 5th gen CV axles will have a groove cut out.

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OEM Flange Nut Cover

43525-35010

If you're sticking with 4th Gen CV axles, you probably won't need to replace the flange nut cover.

If you're installing late gen 5th Gen CV axles, you won't need this part.

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OEM Cotter Pin

95381-04045

If you're sticking with 4th Gen CV axles, it is highly recommend to install new cotter pins.

If you're installing late gen 5th Gen CV axles, you won't need this part.

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OEM Front Knuckle Grease Cap

43442-35060

Fits 2004 to 2024

If you mess up your Grease Cap trying to remove it, you should order a new one. It is critical to keep water out of the wheel hub where the axle nut and cotter pin are.

 

[88Center]

4Runner CV Axle Rebuild and Install Tutorials

Before you remove the spider bearing on your CV Axle, make sure you take a felt tip marker and mark the position of the spider on the splines on the shaft, so you can place it exactly the way it came off.

Also make sure you have all the necessary clamps, boots, clips, seals, shop rags, and tools to finish the job.

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Car Care Nut - Never Replace Your Leaky Axle | Fix Them Instead | Reboot

https://www.youtube.com/watch?v=YH5Cf7uJV5Y

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He gives some really good tips on how to remove and install CV axles.

Car Care Nut - When DIY Car Repair Goes Seriously Wrong! a $1500 Mistake!

https://www.youtube.com/watch?v=OIp4osO8RT4

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How To Replace CV Axles 03-09 Toyota 4Runner

https://www.youtube.com/watch?v=ztEh94ewK38

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One of the best tutorials I've seen on any 4Runner forum. Note, he uses tan grease for the inner boot, and dark for the outer boot. This is opposite of what I did. He also uses different clamps.

CV Reboot Tutorial with Boot Stretch (80+ Pictures)

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This tutorial also shows a complete tear down of the axle, including how to remove the shaft from the CV joint and replace the balls.

CV Axle Disassembly | Toyota FJ Cruiser Forum

 

[88Center]

Complete list of part numbers to get the job done for 4th Gen 4Runner 2003 - 2009, keeping original CV axles

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Toyota Part Numbers

04427-60133 OEM CV Boot Kit
90999-94115 Raremax UBZ

90311-47027 Type T Oil Seal (left)
90311-47013 Type T Oil Seal (right)
90316-72001 Type D Oil Seal (2x)

90178-28002 Flange Nut (2x)
95381-04045 Cotter pin (2x)

3/8" Oetiker Adjustable Rubber CVJ Boot Clamps, 304SS - Durable Ear Hose Clamps - 4,3/16-4,1/2in (106.0-114.0mm)

Differential Oil
Washers for drain and fill plugs

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Tools

To Remove CV Axle from Wheel Hub

• Orion Motor Tech Universal Front Wheel Hub Puller Set

Alternative to Remove CV Axle from Wheel Hub

• Large punch
• 3lb sledge hammer

To Remove CV Axle from Differential

• 18" Heavy duty pry bar or Heavy duty chisel
• 3lb sledge hammer

Alternative 1 To Remove CV Axle from Wheel Hub

• Air hammer / chisel

Alternative 2 To Remove CV Axle from Differential

• CV axle puller

To Remove CV Clamps and Boots

• Cutting pliers
• Razor blade

To Remove Spider Bearing

• Felt tip marker
• Small hammer
• 2 Shop rags

To Install Boots and Clamps

• Painters tape
• Toyota-specific CV Boot Clamp Tool
• Small hammer

To Clean Up Rust and Parts

• PB Blaster
• Brake cleaner
• 10 shop rags

To Remove Type T Oil Seals

• Seal puller
• Clean shop rag to plug hole

To Insert Type T Oil Seals

• Light sandpaper
• PVC - 2" Coupler (from Hardware store)
• Small hammer
• Lots of patience

To Remove Type D Oil Seals

• Hammer
• Flathead screwdriver

To Install Type D Oil Seals

• Light sandpaper
• Rubber mallet

Other Tools

• 3/8" or 1/2" Drive Socket Set
• Small flathead screwdriver
• Medium flathead screwdriver
• Tie-down Strap or Bungee Cord
• S hook hangers
• Latex gloves
• Protective Eyewear