Won't drive in 2wd or 4hi. Just replaced axle shafts.

[ledzep41]

Hey guys,

A little background. About 2 months ago I was driving and at a stop sign going up hill. When I started to go from a stop in 1st uphill there was a VERY loud boom. I wasn't able to drive in 2wd or 4hi and limped back to the house I had just come from in 4lo. I assumed it was the splines on my passenger side axle shaft blowing off as this had happened in 2013. Previously in 2013 I had a bend axle housing and it ended up blowing out the splines on that same axle shaft. I replaced axle shaft not knowing the housing was bent. Fast forward about 2 weeks and determined based on some things going on the axle housing was bent. Replaced that and reinstalled the new axle shaft. that axle shaft had already started to show some wear on the end of the splines.

So after this recent boom 2 months ago I ordered 2 chromoly axle shafts and went ahead and swapped them both out with new bearings etc. Bled my brakes today after work and got in to take her for a test spin and nothing. Same as right after the boom. No 2wd or 4hi only can move in 4lo. Revs freely in any configuration and drives normally albeit with no rear wheels in 4lo. I'm now thinking this most recent boom wasn't the axle splines. It seemed much louder than the first time it happened although there is no way for me to actually verify that.

The drive shaft spins as it would if I was just sitting there not in gear. I'm mechanically inclined but by no means a master at diagnosing things of this nature. Anyone have an ideas?

 

[brillo_76]

Not sure what year you have. However could be your transfer case is messed up and stuck. In 4 hi. If it's limited or 01 or 02 these transfer have actuators to shift it. If J shift Transfer the chain maybe or transmission issues . How are you limping it home? The front driveshaft working?

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[ledzep41]

It's a 3.4 97 sr5 w 5spd. Yes I was able to limp it in 4lo via front wheels.

 

[brillo_76]

So j shifter transfer. Did you try to jack up the rear axle and verify the 4wd is not in bind state as all j shifter are manual 4 wd. They will bind if ran on dry roads. Refuse to come out of 4wd with the shifter.

However if you are actually in 4wd lo and your rear driveshaft is acting like in neutral. I suspect the transfer case as if it was a jacked up 3rd member your driveshaft would be locked with the front.

Will the j shifter shift into all positions or just stuck in 4wd lo?

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[Bad Luck]

Have you checked your rear differential? If it doesn’t move in 2wd then I would suspect the rear diff or possibly transfer case is your issue.

 

[ledzep41]

I can move the j shift between everything it's not stuck in 4lo. That just happens to be the only one doing anything. I inspected the rear differential and cleaned it out when I replaced the axle shafts. Everything appeared to be OK with it. I'll jack it up tonight when I get home and investigate some more.

 

[Bad Luck]

I can move the j shift between everything it's not stuck in 4lo. That just happens to be the only one doing anything. I inspected the rear differential and cleaned it out when I replaced the axle shafts. Everything appeared to be OK with it. I'll jack it up tonight when I get home and investigate some more.

Did you remove the rear diff to inspect it or how did you inspect it?

 

[ledzep41]

Did you remove the rear diff to inspect it or how did you inspect it?

This past weekend when I installed my new axle shafts I cleaned it out and the pinion and ring gear looked ok. I didnt see anything out of the ordinary. No chucks of anything floating around. However I it was just a quick look I didn't get too in depth other than making sure it looked intact. This afternoon I jacked up the rear end and spun the wheels, and as far as I know it is an open differential meaning the opposing wheel should spin in the opposite direction. Correct me if I am wrong. This didn't happen though. I plan on pulling the diff again tomorrow and giving it a much closer look.

 

[Bad Luck]

This past weekend when I installed my new axle shafts I cleaned it out and the pinion and ring gear looked ok. I didnt see anything out of the ordinary. No chucks of anything floating around. However I it was just a quick look I didn't get too in depth other than making sure it looked intact. This afternoon I jacked up the rear end and spun the wheels, and as far as I know it is an open differential meaning the opposing wheel should spin in the opposite direction. Correct me if I am wrong. This didn't happen though. I plan on pulling the diff again tomorrow and giving it a much closer look.

So you did remove the rear diff?

With an open diff, when you spin one wheel the other wheel should spin the opposite direction IF the driveshaft/pinion is stationary.

 

[ledzep41]

So you did remove the rear diff?

With an open diff, when you spin one wheel the other wheel should spin the opposite direction IF the driveshaft/pinion is stationary.

Yes, and I cleaned it and gave it a cursory look but I thought the issue was splines from the axle shaft blowing off(obviously) still an issue. And only one wheel turns so I am thinking there is some issue with the differential.

3rd gen 4runner axle shaft - Imgur

 

[brillo_76]

I have never seen a Toyota 3rd member shear off the axle splines . Granted, I am sure it happens in heavy off reading etc.

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[Bad Luck]

Yes, and I cleaned it and gave it a cursory look but I thought the issue was splines from the axle shaft blowing off(obviously) still an issue. And only one wheel turns so I am thinking there is some issue with the differential.

3rd gen 4runner axle shaft - Imgur

If only 1 wheel turns then you likely have a problem with the spider gears in the differential. The spider gears are what allows for different wheel speeds in an open rear diff. Without the spider gears functioning properly you won’t have any power transferred to either axle shaft. Having to put it in 4lo vs 4hi in order to move doesn’t make any sense to me unless the rear diff was in a bind. Front and rear driveshafts are locked together in 4wd so 4hi should have been sufficient to move around with assuming your front add was engaged like it should have been. How did you shear the splines on the axle shafts off?

 

[brillo_76]

I think you have a damaged 3rd member and now transfer. Whatever took out the splines was not fixed and it damaged the transfer case as those J shifters are the manual style. So when the lever is in position its locked in. (unless things broke etc)

 

[3bears]

I agree with brillo. sounds like your transfer case might be toast....for what ever reason...and I have not seen/heard/read of one go bad without abuse or neglect...well a j shifter anyway

 

[ledzep41]

Finally able to pull the diff again

I finally had time to pull the diff again this morning.

Everything turns as it should when I turn the pinion gear. However, the passenger side where the axle shaft splines plug into (not sure what that part is called on the diff) won't spin with just resting my finger on it while spinning the pinion gear. I can't do that with the driver side. My thought is whatever drives that passenger side is sheared so that the gear isn't engaging. Thoughts?

 

[brillo_76]

I need to look at my spare 3rd member to see what you are referring too. As I am still trying to understand how your stripped 2 axle shafts splines... :/

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[theesotericone]

I need to look at my spare 3rd member to see what you are referring too. As I am still trying to understand how your stripped 2 axle shafts splines... :/

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If the side gear splines are worn it could cause the axle splines to strip easier.

 

[brillo_76]

If the side gear splines are worn it could cause the axle splines to strip easier.

So Essentially, His 3rd member needs replaced or rebuild then. I never seen axles splines stripped unless extremely heavily off road use. So I am kinda scratching my head on this one as it looking like the member is messed up and took out the j transfer case from not being repaired.

 

[ledzep41]

So Essentially, His 3rd member needs replaced or rebuild then. I never seen axles splines stripped unless extremely heavily off road use. So I am kinda scratching my head on this one as it looking like the member is messed up and took out the j transfer case from not being repaired.

In the original post I went through they why. It was because the previous axle housing was bent due to some rough riding.

 

[brillo_76]

In the original post I went through they why. It was because the previous axle housing was bent due to some rough riding.

You bent your axle housing and didn't replace the axle shafts and 3rd member??? No wonder you trashed your transfer case. [ sorry I missed that and when using tap talk is limited ]

My guess is your damaged all of it when you bent the axle housing. And drove around without verifiying all the other components were good in the 3rd member.. Over stressed and damaged the 3rd member. With all the abuse it broke the transfer case.

The FSM shows you how to verify and check a 3rd member along with your transfer.

So you can replace the damaged components with known good parts or rebuild what you got.

Rough riding is an understatement. :/




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