4WD issues after CV Axle install

Hey guys, so yesterday I installed a new OEM CVA on the passenger side of my 06 TRD OR. Everything went relatively uneventful - I did have some issues with getting the new CVA in the differential but eventually was successful. I also changed the front diff fluid as it needed it while I was up there. After everything was back together I drove it around my neighborhood and engaged the 4Hi. Slight turn to the drivers side at slow speed I felt a lot of resistance coming from the front end of the truck - to the point the truck had binding on the front end and would slow down (driving at slow speed). I completely understand 4wd and pavement, this is something entirely different. I drove the truck straight again and I had a really hard time disengaging the 4wd. Basically my front end differential is locking and I'm not sure why. The new CV axle is sitting slightly more inboard than the passenger side by around a 1/4 in or so after looking at the two again after all of this.

I plan to take it to the shop tomorrow but just trying to get some ideas as to what the heck I did. Pinion bearing damaged on install maybe? I have no idea. Any ideas? Thanks!

 

If you were in 4x4 on dry pavement and you turned the steering wheel of course it’s going to bind. You could break components doing that. At the least you need wet pavement or a dirt road. If you think your locker is stuck jack the truck up and spin the tires. I seriously doubt you damaged any bearings especially the pinion installing a half shaft.

 

The hub nut isn’t too tight and getting hot? If jacked up it dose it spin freely with no resistance?

 

It sounds typical with a 4wd system on pavement. If you still felt the same feeling off of a paved surface then I would be concerned.

 

Forget all of the folks saying driveline bind is normal - even though absolutely it is. What you describe sounds like it goes well beyond that. I would say this is the key to your issues.

 

This is definitely not "normal binding." This is more of a completely locked differential to where the new CV axle side is nearly barking the tire from the binding. I've wheeled this truck quite a bit and I'm familiar with driveline binding in 4 wheel drive and this is completely not normal. I'm seeking answers as to why my front end would be locked after I installed the CV axle. Its a very similar feeling as if I've engaged the rear locker only obviously its in the front. The 4wd then remains very difficult to disengage and then clunks fairly hard when it finally does so. One other thing is when driving in a straight line the 4wd engagement and disengagement is normal. It only starts having problems the moment I turn the steering wheel and primarily a driver side turn where the outside wheel (new CVA side) is turning faster than the inside. I only did this twice as I was concerned I would start shearing teeth off if something isn't already majorly wrong.

I'm going to get the jacks out this morning and see how it spins in the air.

 

Did it seem normal before you engaged 4WD? Once it did disengage 4WD did it seem alright again? Both CV axles spin all the time so if your axle or hub are the issue I think it would always be there.

The being 1/4" more inboard seems like the key to me, too. Like it's keeping the diff from turning freely. It's the passenger side, though, maybe it's pushing on the ADD actuator or sleeve?

I think you'd have to try really hard to make the hub nut too tight. The spec for it is 173 ft-lb and to get that I had to almost be standing on my torque wrench.

 

2WD seems to be working without any issues.


I used my split beam torque wrench on it. It may be off by 10 lbs or so +/- but I wouldn't think it would be way off. It was set at 175 I believe (5 increments). I had the FSM manual in front of me with all the torque specs so I was working from that directly (I'm a bit particular with torque specs).

One other strange thing that happened maybe related to the ADD...the first time this all happened and it was "stuck" in 4wd, after I managed to disengage back to 2wd I turned the knob to engage the 4wd again trying to sort the issues out and nothing happened. I mean no blinking light, nothing at all. I turned the knob back and forth a few times and no lights came on at all. I turned the truck off and back on and then drove the truck and then was able to engage the 4wd again with lights seemingly functioning properly.

 

If there's any bind in the system, it won't want to shift out of 4x4. Try the same in dirt, or preferably in snow.

 

My gut is that the CV axle isn't the root problem, the issue is with the right side extension, ADD, maybe the bearing on that side. Maybe replacing the axle is making a worn dog clutch hang up and more obvious.

 

My tire jacked up driver side tire doesn't free spin there is like a binding clunking noise. It takes force to get it to go. I can spin tire like half turn and stops. You might no the problem?

 

Did the locking ring engage when you put the CV in and you gave it a pull to test! Was the old locking ring on the CV you pulled out!

 

Not sure I had the spindles replaced so maybe

 

What do i need to know about locking ring?

 

I am having a similar issue. I read through the thread but it seems to just end without any resolution so i decided to reach out to you directly. I hope that is OK. Any information about your findings is appreciated.

I removed my front drivers side cv axel to replace the boots. When I was done I threw it in 4H and the 4x4 light just blinks although it felt engaged (on pavement). The problem is It did not want to come out of 4H. I came to a stop, selected 2wd and proceeded slowly. I got a huge clunk and it
Disengaged. It does not appear to be seated all the way. Comparing passenger inner cv cup spacing to front diff vs drivers side there is definitely a noticeable difference. I'm going to pull it out and inspect this weekend.