I found "The One", 2001 Sport Ed. TRD SC'd

[BigFishAllDay]

Hey I have your broken CV's cousin. LOL I was fortunate that I "simply" had to drop the diff, remove the ADD tube, drive the broken piece out from the opposite side, replace the seal, put it all back together. I hope ECGS can get you back in action quickly. You're right, it's the price we pay to have the fun and see the things we see. I've gotten that same look from people. LOL

That's an ugly CV break, for sure. I'm sure you've had your share having run 35s on your rig for so long.

I really wish I hadn't had to do those last few river crossings and submerge the diff after the break. Oh well. I have confidence that ECGS will get me set up, but I'm not sure what it's going to cost me considering none of this is even remotely their fault (so probably no luck with warranty work).

I guess I'll be the first to admit that imo I don't take likes all that seriously and I give them away without too much thought. If I am glad I read the post vs not having read it then I'll probably give a like, especially if there are pics. We always need mooore pics.

I am thankful for the pics of remote NM. I doubt I would have ever seen it without T4R. Hopefully someday I can get out there (at least somewhere cool in NM) myself.

You have over 11k posts on the forum. You may do as you please with regard to likes, you've earned it.

I know you are the type who would appreciate my style of photography, because yours are very similar. It's not all rig shots and obstacles, but also the macro stuff, the signs, the infrastructure, and history. A trip is made of many memorable things. There are photos that I post of various sights in NM that you will not find substitutes for anywhere on the web.

 

[smallfry]

I know where that place is. I was there a couple of years ago and camped in the area. You all went further than I did.

 

[Volcom]

Damn, that was an adventure in itself just getting your 4Runner out. Glad you got it home safely. Looks like a killer place to explore! I need to get down to NM more often.

 

[I'mStock]

You trip reports always make me want to travel up your way and explore northern NM but you see, the way my bank account is set up... :juggle:

Maybe '19 will be the T4R's year.

 

[phattyduck]

I guess I'm just getting old, sitting here talking about "the way things used to be on the interwebs."

I had to look around to even find the "Like" button after all this hullabaloo. That's what I get for generally avoiding the Facebook "Like" mentality...

The question I have is this: How are you supposed to disassemble that outside joint in a normal rebuild scenario? I have reassembled inner Rzeppa joints (my Camry has inner and outer Rzeppas), but those have a bolt-on stub that gives easy access to the axle c-clip. Those joints also fall apart accidentally if you overextend them. Lots of fun fondling ball bearings to get it all back together...

-Charlie

 

[Rockdawg84]

That's an ugly CV break, for sure. I'm sure you've had your share having run 35s on your rig for so long.

I really wish I hadn't had to do those last few river crossings and submerge the diff after the break. Oh well. I have confidence that ECGS will get me set up, but I'm not sure what it's going to cost me considering none of this is even remotely their fault (so probably no luck with warranty work).

Before I put in my dual t-case setup I broke a lot of CV's That was the worst. But since the dual cases I have not broken any. I believe that it is because I don't have wheel spin very often and don't get the shock loading I used to. Every cv I've ever broken was the result of a spinning tire catching traction, usually on a climb. Hopefully ECGS can crack it open get it really clean and simply seal it back up. Fingers crossed for you.

 

[BigFishAllDay]

I spent some time this week tearing into the 4Runner, and here's how it went...

I drained the front diff and got about a half quart of water, followed by some nasty looking gear oil and a drain plug covered in what look like the needles from the side bearing.

I got another pile about this size while I was more thoroughly draining the diff prior to sending it back to ECGS.

Removal time was on par with my last go round, a little under 2 hours from wheels on the ground to diff on the ground.

The mating surface for the CV axle seal took some heavy damage and I'm not confident it will produce a good seal in the future.

I popped the stub shaft to see if I had any chance at driving out the broken end of the CV stub. Note the condition of the gear oil on the stub shaft.

The broken end of the shaft peeking through the diff..

Unfortunately, there was no way I could drive it out with the other end in this condition... The exit hole was blocked by the mutilated side bearing...

You can ship these things in a 5 gallon bucket, but you really need the height of a 6 gallon to get any packing material around them. In a 5 gallon bucket the lid will bulge and almost certainly result in a bucket/diff damaged in in transit. My daughter signed off on the packing job as "baby proof" at minimum. The diff left for ECGS in North Carolina on Wednesday with an ETR of 2-3 weeks (pending inspection)... ugh.

Inspecting the side of the break, I found that while I was working the rig up the hill where I broke, the inner cup was rotating and slamming into the rear alignment cam/bolt, making the popping noise I was hearing post breakage.

Which did this to the cam sleeve and bolt... note the bend right at the shaped part of the sleeve, the bolt was bent here as well. New cam and bolt are on the way.

The force of those impacts was enough to bend up the front bracket on the rear LCA mount. I forgot to take before pictures, but these were taken after I had spent a few hours working it back as close to straight as I could get it.

The arm mounts and cycles with no issues, and has full range of adjustment for alignment, and the bushing gets cinched down the way it's supposed to, so I'm just going to live with it as is. I will place a weld on the alignment cam tab that got chewed up to reinforce it a bit.

Close up... notice the indentation behind the top of the adjustment cam that resulted from the cam being hammered by the inner CV cup on each tire rotation.

Passenger side, how it is supposed to look.

Front of the DS rear LCA mount...

Rear of the DS rear LCA mount, still nice and straight...

One of the diff mount cushions is totally shot. I'll be replacing them both.

I pulled the ADD tube apart to have a look at the intermediate shaft and the P/S CV support bearing. The bearing still feels perfectly smooth but rode over 240 miles in gear oil that was in very bad shape. I figure 144,000 revolutions in contaminated gear oil is worth replacing it, so I have a new bearing on order. I started getting some good photos for a write-up on CVs and the ADD system.

 

[BigFishAllDay]

I started looking around and found that at least one of the bushings on the SPC UCAs is toast, so I cut it out, ordered a replacement set of bushings and gathered the tools needed to press the new bushings into the arms.

I had already purchased a set of updated UBJs for the SPCs and will be installing them as well, since the time is right. The current UBJs have 4 years and about 20K miles of service and while still full of grease, with no measureable play in the joint, they felt a little rough when rotating them by hand.

I’m going to refurbish the old arms and either save them as spares, or sell them complete with new bushings to offset the costs of the repair. I used the bottle jack method this time around, and it went incredibly well. I had all four bushings pressed out in under 15 minutes. I simply put enough pressure on the bushing to seat the inner washer against the LCA sleeve, then heated the sleeve with my propane torch. I applied heat for 2-3 minutes until I could hear the "sizzle", gave the jack a little extra twist and out they came. I had the brand new OEM arms on hand to compare to afterward and confirm there was no spreading of the LCAs whatsoever.

After some clean up and paint I have some Whiteline W53377A ready to install.

 

[BigFishAllDay]

I know where that place is. I was there a couple of years ago and camped in the area. You all went further than I did.

It's a nice area, and I'd like to go back and finish exploring a few other sections that we didn't get to check out. If I attempt that river crossing again, I'll probably be tempted to pull some winch line pre-emptively just to help things along. On the other hand, I might just have to face up to it for a rematch to get some confidence back.

Damn, that was an adventure in itself just getting your 4Runner out. Glad you got it home safely. Looks like a killer place to explore! I need to get down to NM more often.

Definitely, and I know you've been there quite a few times as either the recovery vehicle or the one needing help (usually the recovery vehicle, I'm sure). We kept it lighthearted and I tried not to stress out too much during the process.

I was close enough to you that you may have been on the call out list if I had been solo and forced to walk out of there. This spot is about an hour off I-25 to the east on the way down to ABQ, just south of Springer, definitely check it out if you get a chance.

You trip reports always make me want to travel up your way and explore northern NM but you see, the way my bank account is set up... :juggle:

Maybe '19 will be the T4R's year.

I understand, as my budget has been more limited than normal lately, too. Hence less building out of the rig and more maintenance and using it. Gas is cheaper than fancy new parts. This repair will all be coming out of my savings account, which hurts.

I had to look around to even find the "Like" button after all this hullabaloo. That's what I get for generally avoiding the Facebook "Like" mentality...

The question I have is this: How are you supposed to disassemble that outside joint in a normal rebuild scenario? I have reassembled inner Rzeppa joints (my Camry has inner and outer Rzeppas), but those have a bolt-on stub that gives easy access to the axle c-clip. Those joints also fall apart accidentally if you overextend them. Lots of fun fondling ball bearings to get it all back together...

I'm glad to hear there are some like yourself still out there, oblivious to the "like" and using the forum as a forum.

In a normal rebuild scenario, I think you would just clean out the grease as best you can, repack, and reboot. Toyota doesn't sell the individual parts of the rzeppa joint, only the outer joint as an assembled unit including the axle shaft. For that reason alone, I don't think there would ever be a reason to try and disassemble it unless you were just being OCD about removing every last speck of old grease.

Before I put in my dual t-case setup I broke a lot of CV's That was the worst. But since the dual cases I have not broken any. I believe that it is because I don't have wheel spin very often and don't get the shock loading I used to. Every cv I've ever broken was the result of a spinning tire catching traction, usually on a climb. Hopefully ECGS can crack it open get it really clean and simply seal it back up. Fingers crossed for you.

You definitely have much more control with dual cases. I drove an early 90s SASd pickup with a 5 speed and duals a few years back in Moab and I couldn't believe how easy it was to finesse my way up obstacles, even with the 5 speed. With the duals you could shift straight from first to third. It was crazy.

I'm hoping the same regarding the diff repair at ECGS. That CV axle sealing surface on the diff housing is my biggest worry... I think it's going to necessitate a new housing, which may force me to find another diff to send them or face the core charge.

 

[JBurt]

Thanks for posting the repair process. That gear oil is nasty. I'm looking forward to another BFAD writeup.

It sucks to take money out of savings, but I'm glad you have it. At least you have a sweet Tacoma to drive in the meanwhile.

 

[Dirtco]

Damn Nick, all that breakage is sending me down memory lane. Glad to see your tearing into it and getting it resolved, and like Jeff said at least you have the Tacoma to use until the 4Runner is back up and going.

 

[Hepar]

Thank you for not liking. Your cooperation is appreciated.

People are busy, I understand that too. Before the like button, though, we all had to actually reply with a comment if we wanted to participate on the forum. That resulted in a more active forum, more discussion, more debates, people getting to know each other, etc., which is what we all come here for in the first place.

That's an interesting point of view. The "like" button seems good for people such as myself. Which is someone who rarely adds anything very tangible to a conversation, but also wants to acknowledge an appreciation for something. As well as wanting to avoid cluttering up a post with comments that really don't have anything to do with the main topic. Such as this one...:boxer:

 

[theesotericone]

As well as wanting to avoid cluttering up a post with comments that really don't have anything to do with the main topic. Such as this one...:boxer:

In "build" threads I think of-topic in not only OK but often encouraged. I didn't do a build thread but instead did a trails and BS thread. Notice that BS part? I like when people have something to say, rig related or not. Hell, the first two pages of my thread have way more to do with fishing then wheeling. Actually [MENTION=44220]BigFishAllDay[/MENTION] stopped by to correct me and another forum member about some species of fish. lol

 

[farmerjon]

Well, I'm starting a reply now before even getting to the end of this thread, cause there are too many things to reply to! Thanks for the response on the GG build.

Thanks for the technical readup on the increased pressure TRD caps - that was an excellent readup, not too technical and the author wrote that well. Has me wanting to get a TRD cap (which would mean my rig is finally a TRD rig! haha), as I constantly watch my engine temps (same thing as coolant temp, correct?) on my Ultraguage constantly - have replaced and rotated my coolant thermostat to 6 o'clock instead of 12, in temp drops from 212 to 188, but it has crept back up to 196 and has stayed there lately. Point is, this might lower temps by 8-10 degrees again, and I'm not sure how old my cap is.

I like the firetower pics, have a thing for firetowers and always enjoy seeing more of them. The Taco looks good!

I started catching up on this thread after the GG build and had to stop for the night, 5-6 pages short... Little did I know this CV break was waiting! I went back and read your description again - but I still don't really understand why the front driver's CV broke, if front diff was unlocked? Seems like a pretty standard situation - perhaps it looks a lot easier from the video/your description than it was in person? (and no, I didn't get to hear the snap in the video haha). Ah, now I see your explanation that it may have been failing/weak CV ready to go.

I do "like" a lot of your posts, especially if I'm catching up on a lot of them, as a heads up/way of letting you know that I saw and espec. appreciated your post. I try to follow up with a post as well if I have some thoughts to contribute too. I enjoy your threads a lot! I read your posts and info particularly to expand on my own knowledge of these fantastic trucks - thanks to these forums, I know what various components look like - like now I know what a CV looks like w/o the boots and all. And I learn the little things about these trucks - there's something about knowing a lot regarding a subject, especially through experience, that is fun to reveal and assist others with. Like with Dirtco knowing CVs inside and out and you knowing whatever he said you could bank on, that kind of certainty is very helpful at times. I'm jealous of your in depth knowledge of these things and how comfortable you seem to be in fixing things.

The pics from before the break are pretty! I think I would enjoy the southwest, having grown up in the desert combined with high altitude mountains, just a neat combo!

Really like the up close and detailed pictures - really motivates me to get out there and research things like what exactly is the spindle or ADD tube or such. I'm learning a lot, which is refreshing.

It appears I'm only 3 hours from your front diff!

As always, keep it up!

 

[owyheerat]

Nick,
Sorry again about the damage. Thanks for taking the time to photo and post a very informative write up, that I hope I never need....

Durwin

 

[habanero]

Well that was a post I couldn't like. Glad you're getting down to it, sorry it's such a mess. Nice milk-oil. Good tip on the bucket shipping container.

 

[psraff]

Now for the fun pictures, before all the broken 4Runner stuff…

First view of the canyon, looking north toward an orchard planted in the late 1800's. Some pear, apple, apricot, mulberry, walnut, pecan, plum, and osage orange trees are still alive and well.

This was once a fine two story hotel… It was destroyed by a flood in 1904.

(Full history of the area for those interested, here > https://www.newmexico.org/nmmagazine/articles/post/found-lost-93375/)

First and foremost, sorry for your front end. Those are areas I have to learn and prepare for, for sure.

Second, love the pics of history and enjoyed the article. I'm a real sucker for local history!! My goal is to be out of Alaska in 3 years and to see areas like that.

 

[Fishwerks]

The geese and cranes were insane. It reminded me of the old Hitchcock film "The Birds".

I think the CV axle in question may have had existing damage and decided to finally quit at that spot. When it snapped I had actually let OFF the throttle and the wheels were slowing to a stop. It was not a situation that should have caused a broken CV.

Yeah seemed strange when it popped, but you never know I guess. Hopefully the diff doesn't become too much of a headache.

I need to head south to get some wheeling or fishing in soon...

 

[Volcom]

Definitely, and I know you've been there quite a few times as either the recovery vehicle or the one needing help (usually the recovery vehicle, I'm sure). We kept it lighthearted and I tried not to stress out too much during the process.

I was close enough to you that you may have been on the call out list if I had been solo and forced to walk out of there. This spot is about an hour off I-25 to the east on the way down to ABQ, just south of Springer, definitely check it out if you get a chance.

You've got my number, call me anytime you need help.

 

[BigFishAllDay]

Thanks for posting the repair process. That gear oil is nasty. I'm looking forward to another BFAD writeup.

It sucks to take money out of savings, but I'm glad you have it. At least you have a sweet Tacoma to drive in the meanwhile.

You're welcome. I'm glad to have some money saved for these kind of things, too. We have always lived well below our means and saved a high percentage of our income, which has paid off lately.

Damn Nick, all that breakage is sending me down memory lane. Glad to see your tearing into it and getting it resolved, and like Jeff said at least you have the Tacoma to use until the 4Runner is back up and going.

Like I told you by phone, I have been spending a lot of time in your build thread lately and was reminded of just how much front end breakage you dealt with on your rig. If someday I end up on my 3rd, 4th, 5th.. round of this business, I might be looking at a solid front axle, too. It's a pain.

That's an interesting point of view. The "like" button seems good for people such as myself. Which is someone who rarely adds anything very tangible to a conversation, but also wants to acknowledge an appreciation for something. As well as wanting to avoid cluttering up a post with comments that really don't have anything to do with the main topic. Such as this one...:boxer:

I feel you, homey.

In "build" threads I think of-topic in not only OK but often encouraged. I didn't do a build thread but instead did a trails and BS thread. Notice that BS part? I like when people have something to say, rig related or not. Hell, the first two pages of my thread have way more to do with fishing then wheeling. Actually BigFishAllDay stopped by to correct me and another forum member about some species of fish. lol

Some guys just like to see their thread getting attention, regardless of whether it revolves around the build/rig. I lean toward having less BS and clutter in my own thread, in the interest of keeping it readable/searchable. BS threads just remind me of TW, which is 90% BS.

The fish thing had to be set straight... fish are important business.

Well, I'm starting a reply now before even getting to the end of this thread, cause there are too many things to reply to! Thanks for the response on the GG build.

Thanks for the technical readup on the increased pressure TRD caps - that was an excellent readup, not too technical and the author wrote that well. Has me wanting to get a TRD cap (which would mean my rig is finally a TRD rig! haha), as I constantly watch my engine temps (same thing as coolant temp, correct?) on my Ultraguage constantly - have replaced and rotated my coolant thermostat to 6 o'clock instead of 12, in temp drops from 212 to 188, but it has crept back up to 196 and has stayed there lately. Point is, this might lower temps by 8-10 degrees again, and I'm not sure how old my cap is.

I have had a radiator cap fail on me, so I can tell you it happens as they age. So there you have it, a good reason to spend a bit more on the upgrade.

I like the firetower pics, have a thing for firetowers and always enjoy seeing more of them. The Taco looks good!

Thanks, I'm going to miss that truck when it's gone.

I started catching up on this thread after the GG build and had to stop for the night, 5-6 pages short... Little did I know this CV break was waiting! I went back and read your description again - but I still don't really understand why the front driver's CV broke, if front diff was unlocked? Seems like a pretty standard situation - perhaps it looks a lot easier from the video/your description than it was in person? (and no, I didn't get to hear the snap in the video haha). Ah, now I see your explanation that it may have been failing/weak CV ready to go.

I think there was some accumulated damage in my front end and that CV was just ready to let go. It just so happened to let go at that spot. It was certainly not a climb where I would have expected any trouble.

I do "like" a lot of your posts, especially if I'm catching up on a lot of them, as a heads up/way of letting you know that I saw and espec. appreciated your post. I try to follow up with a post as well if I have some thoughts to contribute too. I enjoy your threads a lot! I read your posts and info particularly to expand on my own knowledge of these fantastic trucks - thanks to these forums, I know what various components look like - like now I know what a CV looks like w/o the boots and all. And I learn the little things about these trucks - there's something about knowing a lot regarding a subject, especially through experience, that is fun to reveal and assist others with. Like with Dirtco knowing CVs inside and out and you knowing whatever he said you could bank on, that kind of certainty is very helpful at times. I'm jealous of your in depth knowledge of these things and how comfortable you seem to be in fixing things.

I have always preferred to know my vehicles thoroughly. Lacking that knowledge leads to a sense of dependence on others, for one if you break down, and two if you have trust a mechanic regarding a fair price on repairs. When you're having trouble in a remote location, nothing will calm you down like knowledge. Thanks for always following and for the consistent flow of feedback over the years, Jon!

The pics from before the break are pretty! I think I would enjoy the southwest, having grown up in the desert combined with high altitude mountains, just a neat combo!

New Mexico is an incredible state... very underrated, and I'm thankful for that.

Really like the up close and detailed pictures - really motivates me to get out there and research things like what exactly is the spindle or ADD tube or such. I'm learning a lot, which is refreshing.

It appears I'm only 3 hours from your front diff!

As always, keep it up!

Will do, and I'm glad you're getting something out it all.

Nick,
Sorry again about the damage. Thanks for taking the time to photo and post a very informative write up, that I hope I never need....

Durwin

You're welcome, Durwin. I got your PM btw, but have been EXTREMELY busy with not only the truck but also a family crisis.

Well that was a post I couldn't like. Glad you're getting down to it, sorry it's such a mess. Nice milk-oil. Good tip on the bucket shipping container.

Thanks, Hab. A little more water in that gear oil and I could have put it on some cereal.

First and foremost, sorry for your front end. Those are areas I have to learn and prepare for, for sure.

Second, love the pics of history and enjoyed the article. I'm a real sucker for local history!! My goal is to be out of Alaska in 3 years and to see areas like that.

If one is going to wheel a 3rd gen to any serious extent, I think it behooves them to get familiar with the front end components.

I'm a big fan of history too, and NM is ripe with the cultural and natural varieties. I think you're the first person that has ever told me they are trying to get OUT of Alaska. Everybody I know that has been always talks about how great it would be to move up there. I enjoyed my time there, but don't think I could live there.

Yeah seemed strange when it popped, but you never know I guess. Hopefully the diff doesn't become too much of a headache.

I need to head south to get some wheeling or fishing in soon...

Where are you these days? I saw your location changed to NM, but where specifically? I was hoping to get in touch with you and try to make the spring Moab trip this year, but repairs have drawn out and the 4Runner is still sitting on stands.

You've got my number, call me anytime you need help.

You know I will. Thanks for the genuine offer, Aaron.