I took apart my old and new axle. My main question is why the new axle doesn't have the same range of motion, should I just use the old axle/bearings? I've come this far...
If you have the time and patience and special tools like boot clamp crimpers, rebuilding an original Toyota axle is thrifty, and leaves you with a better axle than an aftermarket replacement. Bob Wilson often reposts the three things you usually get to choose two of: good, fast, cheap. New Toyota axle: good, fast New aftermarket axle: fast, cheap Rebuild your own Toyota axle: good, cheap (cheap if you're equipped for it; less so if you have to buy the tools)
The Car Care Nut has a very thorough video on rebuilding the original driveshaft, and he repeatedly advocates rebuilding, due to shortcomings of aftermarket replacements. IIRC it’s not a Prius driveshaft he’s rebuilding, but still worth a watch: full disclosure: never attempted this myself. (reported post to wrong forum, mod can fix)
We all used to go this in the late 80 early 90 . Or if take em to a place that'd blast em apart on spot and hand em back to me 94 bux a pop . They all went out of business because axle shaft became $75 replacement for most . Do tools hang on wall . The 800 otc wall. Mount spring strut compressor which I did not pay for . And been used twice only cause folks believed that a cates strut could blow you're hand off . Leave you eye less etc . Took about twenty years to quash that ole wives tale. Now large trucks etc is a different story .
For future reference to anyone who may need this information later. You should use a lithium-based grease that is fortified with molybdenum for the outers. Im using Valvoline lithium base moly enhanced grease here. For the inners I'm going with Lucas Xtra strength.