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  #41  
Old 08-27-2017, 10:06 AM
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ScaldedDog ScaldedDog is offline
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Douglas, the stock drive flanges are prone to strip like that. Get a set cryoed and you'll never have it happen again.

Mark

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  #42  
Old 08-27-2017, 10:24 AM
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Quote:
Originally Posted by On the RX View Post
WOW! Sorry about your luck! Out of 3 4runners with a combined 800k on the clocks I have never experienced or heard of that happening.

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Unless you swapped over to full float in the rear, you wouldn't have experienced it.

Douglas, FROR has drive flanges that will hold up.
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  #43  
Old 08-27-2017, 03:13 PM
DouglasVB DouglasVB is offline
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I believe these flanges are from FROR? That was my impression when I got them from Justin anyway. Half shafts I believe were from them as well. This was one of their earlier full floater conversion kits.

Here are a couple photos of the half shaft that is going to need to be replaced:

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Above is what interfaces with the now-failed hub flange.

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Above is the part that interfaces with the differential. Looks like there is some mild wear on these splines, too.

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This is the passenger side. Just a little evidence of wear on the splines.

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This is the hub flange. Looks like this one will go sooner or later as well.
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  #44  
Old 08-28-2017, 12:58 PM
DouglasVB DouglasVB is offline
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Well... it's a bit more than I expected to get this fixed. With shipping I'll be in it for $800.

That's for two new half shafts and two new hub flanges. The hub flanges are a new not-yet-released product from FROR.

It'll be October before the parts are in and I have the truck back together. Oh well. Good thing the wheeling season in Oregon never ends
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1986 Toyota 4runner with all of the desirable features - The Albino Rhino
1988 Toyota 4runner DLX - Goldilocks has gone to a new home!
1989 Honda Pacific Coast PC800
2001 Ford Focus ZX3 hot hatch
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  #45  
Old 11-02-2017, 11:44 AM
DouglasVB DouglasVB is offline
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Well... two months later the parts showed up aaaaaaaaand...

The axle half shafts are 1/4" too long!

I'm talking with FROR to figure out what's going on and what we can do to fix it. At least initially, it looks like there was a miscommunication somewhere that resulted in my half shafts being made just a little too long. The resolution most likely will be me finding a local machine shop to grind off 1/4" of material from the differential splines.

Talk about disappointing. Two months of waiting and then this happens.

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The problem, as I understand it, is that the C clip should be riding flush against the flange. Because it isn't, the cap won't fit over the flange to seal everything in.

The crazy thing is that these half shafts are actually just a tiny (a few thousanths of an inch) shorter than my old half shafts that I was using with Asin hubs!

(yes, this is on a full floater setup)
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1986 Toyota 4runner with all of the desirable features - The Albino Rhino
1988 Toyota 4runner DLX - Goldilocks has gone to a new home!
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2001 Ford Focus ZX3 hot hatch
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  #46  
Old 11-02-2017, 11:50 AM
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Maybe there's there supposed to be a thrust washer behind it?
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  #47  
Old 11-02-2017, 12:32 PM
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Quote:
Originally Posted by DaveInDenver View Post
Maybe there's there supposed to be a thrust washer behind it?
Yeah I thought about adding a washer to make up the difference but the dust cap won't fit because the hole for the end of the axle half shaft is too shallow. Ugh.
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1986 Toyota 4runner with all of the desirable features - The Albino Rhino
1988 Toyota 4runner DLX - Goldilocks has gone to a new home!
1989 Honda Pacific Coast PC800
2001 Ford Focus ZX3 hot hatch
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  #48  
Old 11-02-2017, 01:21 PM
DouglasVB DouglasVB is offline
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It looks like I could hack an M33x60 washer to work. I'd need to clearance out some areas so it'd let the dust cap bolts through but a 4mm thick one would do the job. I'd juse just a little sealant on one side to make a good seal with the flange.

Now where can I get one in PDXland without having to order from McMaster...
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1986 Toyota 4runner with all of the desirable features - The Albino Rhino
1988 Toyota 4runner DLX - Goldilocks has gone to a new home!
1989 Honda Pacific Coast PC800
2001 Ford Focus ZX3 hot hatch
KD7YBQ
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  #49  
Old 11-02-2017, 06:41 PM
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My memory is getting foggy, but I thought there was a splined washer that fit on the axle stub on my '91 front hubs. It would have fit between the hub dial and the hub body.
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  #50  
Old 11-03-2017, 11:36 AM
DouglasVB DouglasVB is offline
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Quote:
Originally Posted by DaveInDenver View Post
My memory is getting foggy, but I thought there was a splined washer that fit on the axle stub on my '91 front hubs. It would have fit between the hub dial and the hub body.
Yeah I vaguely remember that, too. Haven't had to disassemble the front in almost a year though so I forget!

I have a big thrust washer showing up today that should fix the spacing problem (mostly). I'll need to come up with some gasket material to seal the outer edge of the dust cover.

From everything I can figure with my engineering background, it shouldn't matter having the end of the half shaft be just a little bit longer. As long as I'm not jamming the half shaft into the diff too far (which shouldn't matter anyway), nothing is getting harmed. The only problem really is the dust cap not fitting on because its hole is shallow. Adding 1/4" to the overall length of the hub assembly is no problem because the Asin hubs were much longer anyway.

Here's hoping my McMaster order shows up on time today!
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1986 Toyota 4runner with all of the desirable features - The Albino Rhino
1988 Toyota 4runner DLX - Goldilocks has gone to a new home!
1989 Honda Pacific Coast PC800
2001 Ford Focus ZX3 hot hatch
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