My front end is starting to get noisy (again) and I noticed a tear in my CV boot a couple of days ago.

To make things worse, today I installed a set of Aisin manual hubs and ran into problems. At some point, the cone washers were removed with a hammer and they weren't very gentle. One of the holes was slightly deformed and made the cone washer a tight fit. I put the washer and nut on and gently tried to snug it into the hole. Bad idea. I snapped the stud off . At least I got them installed but I can't imagine it's a good idea to cruise around with only 5 nuts holding the hub on.

Have any of you guys replaced one of those studs? It's got to be a press fit from the rear but I didn't take the time to look.

 

Kevin,
That sucks man. Every since your write up that noise drives my ape and I've noticed it's getting worse. I can't wait to get back there and have you show me how to fix that sucker. As far as the 5 studs I would think your alright for a little while especially since I see people driving around with snapped off lug nut studs! I wouldn't use 4WD or go wheeling with it like that though! haha. BTW my RNLTD to Fairchild is 15 Oct.
Joey UK Myers

 

Those studs have metric thread on both sides. If a piece is still sticking out, you could try to use some locking pliers (i.e. Vise) to unscrew the remaining piece.
If it's completely broken off, you'll need a left tap to remove it. It helps when you heat up the hub somewhat. There's a chance there's Loctite on the stud and that stuff loosens at about 120 degree celcius. Don't ask me what that is in fahrenheid.

 

UKMeyers:

That noise is enough to drive a guy insane. I'm afraid my new noise is coming from the axle again, but it sounds different. The axle had quite a bit more play than it did when I did the spindle bearing install.

See you when you get here. Hopefully, I'll have all my stuff straightened out and we can do some wheeling. After we take care of yours, of course.

4runner4ever:

I'm glad to hear the studs just thread in. I believe there is enough to get a hold of, but I'll bet it'll be tight as heck. I'll try heating it up to 248 degrees fahrenheit and see if that helps .