CV joint housing

[woodster22]

I have a 2004 Runner and I'm replacing the right drive axle but cannot get the CV joint housing free from the differential. I've read both prying and hammering with a brass drift as options, but I wan't to make sure I won't do any damage to the differential. Also, the manual reccommends draining the differential fluid, but I can't do that due to a practically welded shut drain plug. I wanted to make sure that there wasn't a vacuum being created by not being able to drain it?

[ncrunner]

The end of the CV axle that is in the differential has a spring-ring that holds the splined portion of the axle in place. This is causing the resistance preventing you from removing the CV axle.

The service manual shows the use of a slide hammer with a special "hook" that grabs a groove on the CV housing. I borrowed a slide hammer from Autozone but the it did not have the special "hook" that Toyota designed on thier special service tool (SST).

I used 2 long hose clamps and clamped one of the arms of the slide hammer's extention onto the CV housing and with only a few slides, the housing and axle popped out. For you, once it is removed your diff lube will pour out.

A couple things to look out for during this job:
a) make sure the new CV axle is of high quality. Look at the surfaces where the seals will wear on. My new CV axle had slight imperfections. I ignored them and now my seal is leaking diff lube. I have a hunch the less-than-polished surface of the new axle isn't sealing on the diff seal.
b) check to make sure the new CV axle has the same seals and metal dust shields. Mine did not so I had to carefully re-use a seal and the shields from the old axle.
c) for the slide hammer trick to work, you'll more than likely need to cut the boot off the diff side of the old CV axle and remove the sliding portion of the joint. this will give you more room to attach the slide hammer arm to the CV housing.
d) do a search for 04 front CV/shaft problem on T4R.org. There are some good photos of the setup of the slide hammer.
e) take care not to bump the diff seal when removing and installing the CV axle.

Hope this helps.

J.Peter.B
Winston-Salem, NC