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86-95 Trucks & 4Runners 2nd/3rd gen pickups, and 1st/2nd gen 4Runners with IFS

half shaft pops out when in 4wd

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Old 03-15-2015, 05:52 PM
  #21  
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It's ok I'm in the same boat. All i can think to do is just replace everything and see where I end up. I think I'll start with the wheel bearings and then rebuild the hubs and the off to the bushings and the ball joints and see where I end up. Worst case I have a whole new front end. I'll prolly do it before I drop in the new 22re I just picked up. If I find the source of the issue I'll be sure to post up. Thanks again for everyone's help and suggestions.
Old 03-15-2015, 05:58 PM
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See if you can find measurements on half shaft length and compare it to yours, extended and compressed length.
Old 03-15-2015, 06:05 PM
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I'll do some digging and see what I come up with. I will probably have it off again this weekend I'll measure then.
Old 03-16-2015, 10:17 PM
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Maybe the inner tulip is binding and not allowing the shaft to lengthen as it needs during steering? If you pull the CV does the tulip have free play?

Also, in the pic you showed with the CV pulled partly out of the knuckle, if you steer hard can you crawl under and push the CV back into the knuckle?
Old 03-17-2015, 05:57 AM
  #25  
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I'm still thinking you might have the wrong half-shaft in there, one that is too short.

I think I'd make a trip to the local Toyota dealer and find out for sure what the proper part number is for your vehicle, and make sure you get one the right length.
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