Quote Originally Posted by Merrell90 View Post
I see, do the inner axles that go into the differential wear down quickly in this condition? Also, What would explain the clunk noise when the TOD %100 engages/disengages? To replace the shafts, it would be outer axle shafts?
The green cup is actually the outer race of the CV joint. If you're getting the clicking sound then it's likely that the green cup has some divits worn into the grooves where the bearings ride (that was my finding on a statistical sample of one).

Most people end up just needing to do a good cleaning - new grease - new boots ... but a few of us weren't so lucky. I was able to find a shop that ground out the grooves on the green cup and then installed oversized bearings. That worked fine for me. Another member found a shop that filled the grooves with a welder and then machined them back to OEM tolerances. That worked out well too. Everyone else that had excessive wear of the joint either went with SureTrac shaft replacements or were able to source a set of used shafts from the boneyard.

My recommendation is to just try the boot replacement first. Even if the clicking persists, then you've bought yourself some time to source new shafts.