80 series drive line clunk

Submitted: Monday, Mar 19, 2012 at 13:34
ThreadID: 92630 Views:3792 Replies:4 FollowUps:4
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I have a 1996 80 series TD auto GXL which i have just installed a part time kit.
It now has the dreaded clunk like the FJ cruiser's have. As you come to a stop it clunks or if you take off it clunks. Place it in neutral when stopping and no clunk or brake very lightly to a stop and it usually won't clunk. I grease the slip joint and clunk is gone for about 3 days then gradually comes back.
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The FJ cruiser fix by toyota is to replace the drive shaft.
A local Sydney shop wants to replace the slip joint and unis for about $500. Does this sound about right to anybody whom has had this work done or does anybody have any suggestions where to get this repair done?
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I am a mechanic by trade and I'm 100% sure it is the slip joint as it does have some play in the splines. I am thinking for $500 I can almost buy a new one.
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Any suggestions would be greatly appreciated.
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Scott
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Reply By: Whirlwinder - Monday, Mar 19, 2012 at 17:04

Monday, Mar 19, 2012 at 17:04
120scruiser,
I have a 97 80 series with aftermarket turbo and 237000kms. It too has a clunk like yours and like you, I greased the slip joint and the clunk went away for a few days. I had the slip joint replaced but the clunk is still there so I am scratching my head. Try removing the rear tail shaft and driving on the front axle only to see if the clunk is still there. Could be we both have gearbox/transfer case backlash.
Please post with your findings, good or bad.
Ian
AnswerID: 480807

Follow Up By: 120scruiser (NSW) - Monday, Mar 19, 2012 at 18:41

Monday, Mar 19, 2012 at 18:41
Hi Ian
Is yours a part time or full time 4wd model?
Mine was a full time but I have converted it with the heavy duty Marks 4wd adaptors kit.
Scott
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FollowupID: 756247

Follow Up By: Whirlwinder - Monday, Mar 19, 2012 at 18:43

Monday, Mar 19, 2012 at 18:43
Mine is part time 4wd.
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FollowupID: 756248

Follow Up By: 120scruiser (NSW) - Monday, Mar 19, 2012 at 19:09

Monday, Mar 19, 2012 at 19:09
It doesn't seem to be a problem with the full time 4wd. Mine only showed up once converted to part time. The full time's front shaft must soak up the clunking.
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FollowupID: 756253

Reply By: hamo - Monday, Mar 19, 2012 at 17:38

Monday, Mar 19, 2012 at 17:38
Hi Scott
Its a common problem with the 80 series. There even was a toyota recal for it.
Unfortatly that finished in 2010
I had a heavy duty tail shaft made up for mine by hardie spicer not cheap at $1000.

Get the slip joint replaced

Hamo
AnswerID: 480810

Reply By: Bob Y. - Qld - Tuesday, Mar 20, 2012 at 14:42

Tuesday, Mar 20, 2012 at 14:42
Scott,

I priced a genuine front drive shaft for a 79 series ute, and Mr Toyota wanted $1400!!!

Bought a new after market one from Queenslandlcruisers, in Rockhampton, for about $350 - $400.

Probably should've bought a couple at that price.

Bob.

Seen it all, Done it all.
Can't remember most of it.

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AnswerID: 480899

Follow Up By: 120scruiser (NSW) - Tuesday, Mar 20, 2012 at 16:02

Tuesday, Mar 20, 2012 at 16:02
Thanks Bob
I will google them.
Tumut Toyota used to have some great deals but haven't seen them advertised lately. They used to advertise in 4x4 trader but that mag doesn't seem to exist anymore.
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FollowupID: 756306

Reply By: 120scruiser (NSW) - Thursday, Mar 22, 2012 at 20:16

Thursday, Mar 22, 2012 at 20:16
I pulled the tail shaft out and pulled the slip joint apart.
I cleaned all the grease out of it and cleaned it all up.
I put it back together and installed it and after 2 days it appears fixed.
Looks like it may have just had a hydraulic lock with grease.
We will see how it goes after a few more days of driving.
AnswerID: 481119

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