92 4Runner front drive shaft problemo

Submitted: Tuesday, Oct 07, 2008 at 21:52

ThreadID: 62362 Views:2558 Replies:2 FollowUps:3

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Louie the fly (SA)

We went away last week and during our trip (on some rough stuff in the Flinders Ranges) a noise developed under the car. When I checked it I found that the front RH drive shaft flange is a bit wobbly at the diff end - the stub shaft moves about a bit where it enters the front diff. It all seems to work OK - drives fine in 2WD (drove home 550km last Wednesday with no problems whatsoever), and it still works fine in both low and high range 4WD. It appears to have thrown out either grease or oil over the suspension.

My first thought was that the bearing in the diff may have collapsed but if that was the case there would be a horrible crunching noise and things would have soon come to a halt. The noise is more of a slight rattle.

Can anyone shed some light on what the problem might be and whats involved in fixing it?

Cheers

Louie

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Reply By: Dunaruna - Tuesday, Oct 07, 2008 at 22:58

Tuesday, Oct 07, 2008 at 22:58

It is a common problem for that era 4runner/hilux. The right hand side of the front diff has an extra long flange support and it often flogs out the carrier bearing seat.

2 ways to fix it: Find a good secondhand diff housing or get your diff housing repaired. The repair can also involve case hardening of the carrier bearing seat but that costs $$$$$.

AnswerID: 328855

Follow Up By: Louie the fly (SA) - Tuesday, Oct 07, 2008 at 23:56

Tuesday, Oct 07, 2008 at 23:56

Thanks Dunaruna. As I understand it the stub shaft is splined into the diff gears. If the bearing housing was flogged out I would have thought there would be a fair bit of noise but there isn't. I found some info on the web as the manual doesn't list anything to do with the front diff. It shows that the right hand side Gear Shaft, as they call it, protrudes a small amount from the housing (as opposed to the LHS which is about 30 odd cm long) and is mounted on a tapered roller bearing. I can't work out what holds the inner race from falling out. Is there a locking sleeve or something in there, or is it held in place by a thrust washer? From the section view it doesn't seem to have either. Apparently the gear shaft comes out with the use of a slide hammer. Spose I'll just have to pull it out and see.

FollowupID: 596164

Reply By: Stephen M (NSW) - Tuesday, Oct 07, 2008 at 22:59

Tuesday, Oct 07, 2008 at 22:59

Hi there Louie, have you tried turning the wheel full lock both ways ?? and idling forward as if doing a u turn. If so is there a clicking noise ?? if there is it would be a CV joint stuffed. I would say its stuffed anyway by the sounds of it. If the crap thrown around the suspension and under the wheel arche is is like a black/silvery grease then that is the grease from the cv joint (this should also indicate a torn rubber boot around the cv. If its oil from the diff then you have more serious issues deeper within. If the crown wheel has thrown a few teeth (which can be common if you have lifted the wheel while giving a bit of right boot then the wheel comes back down and bites the dirt again) and with hubs locked in I presume you would be getting a fair bit of noise but you are obviously not so I dont think you have any issues with the diff centre its self. Hope this gives you a little bit more to look for. Im no mechanic so could be totally wrong with all of the above, just what I have seen and heard myself. Regards Steve M

AnswerID: 328856

Follow Up By: Louie the fly (SA) - Tuesday, Oct 07, 2008 at 23:33

Tuesday, Oct 07, 2008 at 23:33

There is no clicking noise and the boots are as new with no splits. The diff oil is at the correct level and everything works fine. I will drain the diff and check for metallics but it all seems very quiet. It was subjected to some serious "wheels up action" but it still all seems to work. Just a bit wobbly. Bit of a mystery.

FollowupID: 596161