Off Road Solutions Tundra CV Axles
Published by Trails Less Traveled on April 9th, 2004
INTRODUCTION
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We are revisiting the Total Chaos long travel front suspension on our project Tacoma to install the 4wd CV axleshafts. Because 2wd Prerunners and 4wd Tacomas share the same suspension, we chose to write this part of the installation as a separate article in order to keep the steps clear.
Total Chaos Fabrication designed their long travel front end to be 3.5” wider per side (the same track width as Tundra trucks), which allows Tacoma owners with automatic hubs to purchase stock Tundra CV shafts and install them without any modifications or additional parts. Tacoma half shafts utilize a tripod joint instead of a true CV, tripod joints are inferior in comparison to the true 6-ball Tundra Constant Velocity joints. The additional strength and range of operation allows the Total Chaos Tacoma long travel front suspension to run the full 13” of available vertical wheel travel, retaining 4wd (with minor modification).
Manual locking hubs reduce wear by disengaging the drivetrain (CV axles, differential and front driveshaft) during 2wd operation. Unfortunately, manual hubs started getting hard to find on Toyota trucks around the mid-nineties, when Toyota began to phase out manual hubs in favor of ADD differentials and automatic (full-time) drive hubs. Manual hubs are an increasingly uncommon on Tacomas’ newer than 97/98, and Tundra trucks never even had the option.
Off Road Solutions manufactures manual hub conversion kits for Tacoma and Tundra enthusiasts that want to replace their automatic hubs. They have a range of conversion applications available to fit Tacomas, 4Runners and Tundra trucks, with or without ABS. We were lucky enough to find an early model truck equipped with manual hubs, so we didn’t need all of the conversion parts, but we did use their replacement/upgraded 4130 heat-treated intermediate shafts and outer spindles with modified OEM Tundra inner CV’s.
INSTALLATION
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The front differential was removed along with the front driveshaft during the long travel suspension installation. It is important to note that removing the front differential is NOT necessary, and is only shown here out of the truck for illustrative purposes. Also, because we are installing the CV shafts after the suspension, there are a few redundant steps.
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Turn the locking hub dial counter-clockwise to the free position, remove the six bolts from the outer face of the locking hub and then remove the outer half of the locking hub.
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After removing the outer half of the locking hub, remove the six nuts that secure the inner half of the locking hub to the spindle. Under each nut is a split tapered seat cone washer, and they can be difficult to remove with without damaging them. Penetrating liquid and a combination of tapping/prying with a flatblade screwdriver should persuade the lock-washers. Remove the bolt and washer from the end of the axleshaft (shown here in the middle of the picture) before removing the inner locking hub assembly.
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If the CV axles are being installed at the same time as the front suspension, the axles must be installed before the upper A-arm is bolted to the spindle. If the axles are being installed after the fact, the only redundant steps are to remove the locking hubs and the upper A-arm spindle bolt (spindle bolt shown here).
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Pivot the spindle away from the frame on the lower ball-joint, and remove the outer end of the CV shaft from the backside of the spindle at the same time, being careful not to strain or kink the brake lines. The inner CV joint is held in place by a simple snap-retainer and is easily removed with a pry-bar (shown with the outer CV axle shafts & differential removed for clarity). The snap rings are considered a single use item, and should be discarded after removal.
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In order to safely and reliably achieve the full 13” of travel available with the Total Chaos kit, the Tundra inner CV’s need to be modified. The stock Toyota Inner CV boot attaches to a reduced diameter ring, this is where the interference takes place. In order to create more clearance and allow the inner CV to fully articulate, the inner CV boot retaining surface needs to be cut off. A new larger diameter Porsche CV boot (available from Kartek , PN: KTKBAT101) can then be attached to the outer surface of the inner CV.
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The first thing to do is remove both of the clamps that hold the inner CV boot on. Slide the boot down the axle and wipe away excess grease exposing the the inner retaining ring. Using C-Clip pliers, remove the retaining ring and slide the inner CV off.
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Clamp the inner CV into a vise and stuff a clean shop towel into it to keep grinding dust and debris out of the CV balls. With a cut-off wheel or a hacksaw, remove the inner lip surface. Smooth any burs or jagged edges left behind with a file or emery cloth.
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Slide the new boot over the axle and then slip the inner CV onto the splines and reattach the retaining ring. Pull the Kartek boot over the inner CV and fasten with new clamps.
Installing the new Off Road Solutions Tundra CV shafts is as easy as removing the old parts was, in the reverse order of the steps we briefly covered above. Consult your owner’s manual for further details and torque specifications. Here you can see the completed installation, from the front and rear view at full extension.
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