Third gear and CV gone all in one day

[4Hilux]

Hi Doug - sorry to hear its getting more expensive to fix (I hate it when things 'snowball' like that....). Might seem a dumb question, but any of you guys fitted FWHs to the front end of a new Hilux?? Can it actually be done?? This at least means they would be easier to get home in, if a C.V did break, as the shafts then would'nt be rotating. (Been there, done that in a Surf, that broke a CV with the fixed front hubs......)

[Doug67]

9w6vx

I would not get warranty due to the lift I have.

4hilux

I have heard of people talking about FWH but I don't think anyone has fitted them. I had no problems driving as the driveshalf came out of the inner joint.

[Wade]

Sorry to hear about the expense bill Doug!!
What about the 120 series Prado CV's. I think they fit

Cheers

Wade

[9W6VX]

Doug,

It's a shame that Bilstein don't provide warranty claiming that your lift is excessive.

How much lift do you have upfront anyway?

Cheers mate

Brendon

[Doug67]

wade
Spoke to Ken from Ultimate and said the 120 series have different splines, I did buy some 95 series and found the inner joint that he said to use was different as well so I don't know. I found today the Hardy spicer supplied cv are 5mm shorter than OME and the new cv is binding up when the wheel is in the air so I sending to Toyota tomorrow to have them fix the gearbox, hopfully all goes well then I'll look into the cv problem again.

9W6VX
Not sure of the lift height atm but 790mm from the bottom of the rim 16" to the bottom of the flair (aftermarket flair)

[Wade]

Thanks Doug. Good Luck with Toyota. I hope it goes well for you mate

[9W6VX]

Doug,

Roger that mate. Good luck with Toyota San!

Cheers

Brendon

[bms]

Anymore info on what the prob was Doug and have you had some joy from Toyota re the gearbox

[Doug67]

bms

As the lux went in three days after the warranty ranout Toyota said customer to pay 50% so was expecting a large bill so can not coplain when they said $300 for my half. They said a number of teeth had broken off third gear they said to come and have a look but have been working away. I decided to have them throw in a cluch kit while there at it $945 installed and $50 machining costs for the flywheel. I'll post some photos on the weekend showing bent diff perch brackets.

[McSumWay]

Is it the standard clutch or have you found a HD replacement??

[Doug67]

I could not be bothered with a HD one as I heard from 10K that the HD Exedy clutch installed on the Taipan truck is slipping.

[10K]

Doug,

Give me a call if you need a clutch.
$680 for a HD custom from a place in QLD. Should be pretty good, these guys were recomended to me by Exedy.

I'll post details/photo's after the install next week.

Cheers
Matt

[McSumWay]

So Doug - give us an update on progress

[Doug67]

ok tonight

[McSumWay]

still waiting!!!

[Doug67]

Yes as per the other post I was tied up last night, I need to up load some photos.

[Doug67]

Toyota wanted $500 for the outer shaft and $800 for the whole thing, ended up paying $145 and bought two from Hardy Spicer. I posted previosly $160 above because thay said that what it should be. I installed the day before my warranty ran out on the Lux, once install I noticed some not right the drivers side of the diff was higher than the other side but just wanted to get the Lux in to get the gearbox fix under warranty so started to drive to Toyota but first corner the CV pulled out again so back home topull apart and some phone calls for a couple of brackets that hold the diff to the chassis, toyota wanted $200 ea but bought a couple from a wreckers for $75 ea. I could not tell by looking at them they where bent until I compared to the others.

Drivers side diff support bent one at the top.





CV from Hardy Spicer



New CV on top and old one below. The outer shalf pulled out of the inner Tripod.



Passenger side diff support bracket, could not see it was bent but replaced anyway.



When the second cv pulled out it knocked the shocky out of alignment sent to climax who said was fixable straightened and welded both sides.



Need to hit the inner tripode out with force on lugs provided. photo showing diff and support brackets.






TBC

[Doug67]

Some special tools reqired. Torque wrench,small and large 10mm hex head for oil filler plugs, 35mm socket for the Toyota bearing nut, 41mm for the after market one, hand tap found the steel in the diff to be very soft and wanted to cross thread all the time, also a piece of angle iron to knock out the inner tripod and a piece of tube to extend your ratchet for better leverage to get some of the nuts loose, last two items not in photo.



I installed the new cv but found when the wheels where of the ground the drivers side wheel was binding so a Toyota cv may be a better option so due to tis I have placed 11 wasshers under the diff support brackets to drop the diff a bit lower I replaced the bolts to 130mm x 14mm, the binding has now been fixed, I intend to get another diff support bracket that attached beneath the main part of the diff and modify to lower it about 5mm to help a bit more. So I'm of up the bush behind me tomorrow and to Stockton beach on Sunday to give it a good test, I hope all is now well.

[McSumWay]

Fingers crossed

So which came first -- the bent diff or the broken CV??

Chicken and egg???

[Doug67]

The cv came out which pushed the diff bracket upwards