Rear axle cut housing

[Broski]

Update Please. How did the rest of the project go ?

 

[thrillerdjc]

I got the rcv shafts had to drill out hubs for new studs. Driver side went smooth but passenger side was a bit tought to get in. Had to mallet the shaft in. The sleeve was tight. Now the locker won't engage. I'm thinking the sleeve is damaged I shouldn't have to hammer it threw there. I think it's binding up on the sleeve that's why it won't lock up.
I hope that made sense these beers kicking in

 

[thrillerdjc]

Also the previous owner did not have the splash guards in there. What is the issue to not having those

Truth be told, I have never have had to do this. I have had my OEM Locked diff & Axle in and out many times. I do know that you won't be able to get the diff out with any amount of the axle still stuck in there.
I can't find the thread but I have read about this issue and they cut in the back. I did find this thread and they also talk about cutting the back in the splash guard

Unable to Remove 80 Series Rear Axle Further than 2 Inches

forum.ih8mud.com

You don't want to cut into the OEM truss on the bottom of the housing you want to keep above that.

 

[Broski]

Ya torching as close to that sleave may have damaged it is should be easy to check refer to post #17
There's a bolt 10mm socket to remove it then you should be able to slide the fork over or at least tell if the sleeve is jammed.

 

[landtank]

the RCV shafts might be more prone to twisting. Attached is a drawing on how I eliminated the problem. Basically you are eliminating the spline area that is not used when the diff is locked. So if the axle twists the splines that would normally create this problem aren't there.

 

[NeverFinis]

the RCV shafts might be more prone to twisting. Attached is a drawing on how I eliminated the problem. Basically you are eliminating the spline area that is not used when the diff is locked. So if the axle twists the splines that would normally create this problem aren't there.

RCV does say the following:

Ultimate 300M Toyota FJ80 Rear Full float axle set. Designed to work with all differential types: OE open carrier, Aftermarket lockers and OE Electric locker. Updated shaft design to aid in known OE Electric locker issues (with axle twist). Backed by our "No Questions Asked" limited lifetime warranty.

My RCV right rear axle has two splined areas.

 

[landtank]

nice, That drawing i posted was from 20 years ago and it has been in circulation. Glad somebody did something with it.