Ok next was the drive shafts. I pulled them out and two of the uni joints were really quite tight. That gave me hope, especially the rear on on the transfer case side.
My intention was to remove the shafts, take them to my dads joint and press them out using his bearing press next time i go home in a few weeks. But i watched a few Youtube videos of people belting the old ones out with sledge hammers. It looked super easy as those joints seemed to just fly out so i thought ill save the 2 week wait and do it at home.
That was a massive mistake! These joints were ridiculously stuck in. It was like trying to move an echidna once it has dug itself in! I was belting the absolute bejesus out of these ****ing things with a big sledge hammer and a 24mm socket. They did come out eventually, some of the really stuck ones i hit them with the angle grinder. It would have been a lot easier if i had an old 9 inch angle grinder, mine was a tiny bit too small.
After a few hours of smashing the s*** out of these things with Thor's hammer they eventually came out. I was a bit scarred at this point. I'm thinking surely i have bent the housings a bit doing this, but at the same time i'm only belting the joint so it shouldn't do anything to the housings.
I fully recommend NOT doing this technique and after some reading after the deed i read a heap of people saying the same thing. Take the shafts out yourself and take them to your local mechanic and get them to press them in and out!! That was an incredibly non enjoyable experience and the good feeling you get doing something yourself doesn't outweigh the pain and the potential for damage you get by doing it yourself.
I made a really stupid **** up when installing these things. There is 4 circlips per uni joint and when installing one i could only find 3. I searched everywhere and stripped my shed but i could not find the 4th one for the life of me. I gave up thinking Toyota must have only given me 3, which i new was bull****, they never **** up!
After throwing a tantrum i bought another OEM uni joint just so i could grab one of the circlips out of it. The ones i removed were a fair bit smaller than my new OEM ones.
Of course once i bought the new one, i put my magnetic rubber vice inserts onto my bench vice and one of them didn't sit right, I'm confused what the hell is going on and i check the back of it and there is the clip!! It was stuck to the magnet the entire time. $70 down the drain, now i have one spare uni joint. The first ones lasted 380,000 km's, i highly doubt i'll ever do enough km's to ever need to replace them again. It looks good in the box on the shelf at least.
While out the rear pinion seal was leaking a bit. I bought some new seals ages ago so i thought now is the time to do it. It wasn't dripping at this stage but it was leaking slowly and there was oil building up on the bottom of the diff.
It all went really smoothly, i reused the staked nut which isn't ideal but i counted the turns to remove the nut and counted them back in and it ended up in the perfect spot. I tried the trick freezing the seal in the freezer before i installed it and it seemed to work really well, it fell straight in.
I tried the same trick installing the new OEM uni joints, putting them in the freezer first then installing them using my bench vice. This worked really well, they went in heaps easier than they came out.
One of them was a bit tight for my liking in the end, i was a bit worried i knocked the cup too far in. But i think it will loosen up once installed and spinning. The other 3 worked fine.
I painted the shafts while they were out and they all look super good. I didn't take any photo's, i might next time i go to the shed.
This job took way to long for my liking, but whenever i decide to paint stuff it really blows the job out.
I took it for a test drive and the clunk appears to be gone!! I couldn't believe it, i'm thinking it must have been that gearbox mount. I took it on a super easy dirt track 4WD and it wasn't clunking. I'll reserve my judgement till i do a proper low range trip. If the clunk is gone i'll be over the moon happy.