Outer CV replacement

Ok folks, this is a writeup / report on replacing the Gen II outer CV joint.

As most of you know, the Toy service manual knows only an code for the cv and axle shaft assembly. Yet you can actually purchase only the outer CV as a replacement part. The CV is not designed to be pulled from the axle, not at least with your normal shop tools. The only way to remove the old joint is to tut it to pieces :-D

As with any write up, I will not take any responsibility if you attempt this and fail miserably or kill your self in the process. Use safety gear and do not try to rush things, it's the best way to F**k things up.

Start by removing the base of the shaft. Cut with a 1mm disc right behind the ABS ring. Take your time and keep the CV cocentric in relation to the axle shaft, this way your 100% sure to cut only the CV.


As you can se, the base of the cup begins here right behind the ABS ring...


Now cut the outer race and the bearing cage in three pieces. Make cuts at approx 120 degrees apart. Once you have removed the outer race and the ball cage, make three deep cuts to the inner race. Be careful not to cut through and harm the splines of the axle shaft. Be careful also nit to cut the C-clip which you can barely see at the tip of the shaft at this point. As most adept of you may noitice, I have cut the end of the axle shaft when I was removing the CV base. This is not an problem as long as the C-clip groove does not get damaged.


Use a big puller to crack the inner race in pieces. You have weakened it with the thee cuts so it should break in to pieces. If you need to use big torque on the puller, you probably have too shallow cuts. Cover the inner race and puller wits a rag or something, because the inner race bits may fly with high energy.


The freed axle shaft. Keep the C-clip which is on the groove, because it is likely a better quality one than the one which comes with the replacement CV...


Cut an opening to the grease pack which comes with the CV. Squeeze 50% of the contents to the center of the inner race, so the grease fills the joint. You can slide the cv on to the axle shaft splines to help the filling process. The grease should squeeze through all around when you do this.


Before installing the joint, place the cv boot on to the shaft first. Then install the C-clip to the groove. You can help it stay centered by putting a dab of the CV grease on the groove. It is essential that the C-clip is centered in relation to the axle shaft, otherwise you will have a hard time. Squeeze the rest of the grease on to the CV and slide it in to the axle. You may have to tap at the CV to get it to snap in to place. The click - sound is quite well audible when the CV locks in place. And yes, you need to trim the CV clamps, can't leave them flapping around like that. Your replacement CV may also have a divverent type of clamp ;-)


This was the hard way to replace the outer CV, but here in Europe we don't really have the selection of ready built full axle shaft assemblies. Except right after I had changed the CV, I found a online shop which had the SKF made CV+axle combo on sale for 80€. The SKF CV was on sale for 55€.
I think I still made a big save on the job because when done this way, you don't need to refill / replace the big €€€ trans oil which costs close to 20€/liter at the local Toyota shop here in Finland.


If this was helpful to you folks out there, Your'e welcome

 

I'm barely knocking the 100k mile mark (157k km to be exact) First set of front wheel bearings and this CV have now been replaced.

The CV boot had torn, otherwise nothing really wrong with it. We just get salt on roads during winter and that stuff goes everywhere. The joint had emptied out quite well from the grease and what was left, was pretty badly contaminated grease and this set me on the path to replace it now and not maybe 20k km's later.

Although looking at the bits of the old CV, I really could have gotten away with just cleaning it and replacing the boot.
It would have been as labor intensive and costlier path to take the axle shaft assembly out and clean the CV properly, grease it up etc...

Not sure if this was the best approach, but it sure was fun