Rear diff cover

As many people know toyota sometimes makes things hard for no apparent reason. The rear diff on many first gen tundras when exposed to salt rust out and begin to leak. The DIY method of fixing for many is J.B weld. I’ve tried I have 3-4 things of jb weld on that thing and she’s still pissing. So I have priced out the new cover for it. 75 bucks what a steal but has to be welded on. Now I am a shitty welder but could do it my only concern is what happens when I blow the rear end and need to rebuild it. If I weld on my cover I won’t be able to do it without cutting it off. So what I am asking is is their a way to drill and tap holes into the axle so I don’t have to weld it on. I would ya gasket maker so it wouldn’t leak.

 

For the weld-on cover, I'm thinking you would need a certified pipe welder (or similarly qualified) to get a leak-tight weld joint. Regards drilling, tapping for plug, rust occurs generally and seldom at a single point, so there is likely to be thinning all around the leak that will soon rust through. Considering the debris from the cover removal and the welding procedure, it is probably easier to simply transfer the internals to a new housing or replace the differential complete. Previous threads on this problem below:

https://www.tundras.com/threads/rusted-leaking-rear-differential-cover.27684/

https://www.tundras.com/threads/replacing-differential.59874/#post-1570269

 

With Toyota axles, the gear-set is accessed through the front/input side as opposed to how it's done in a typical Dana or Spicer axle in which it's accessed from the rear.

A lot of heavy duty axles are set up similar to the way Toyota does it. For example, these are from a Deuce and a half. Granted these input at the top, but it's the same principle: the gears are accessed from the input side, and the opposite side is a welded-on cover.

 

After talking to a SEM rep I’ve been told I can use their adhesive products to so called glue it on and then seam seal around it

 

You're going to cut off the old one, right?

 

Sorry for the month late reply yes I will be cutting it off this whole corona virus thing has delayed my progress on the truck I ran into a seized caliper so I’ve just replaced calipers rotors and pads as it was a must do

 

Dorman sells replacement covers for fairly cheap. welding them on isnt too much of a challenge...

 

I’m gonna buy the doorman cover and use the SEM product to attach it my only issue with welding it is getting a clean mettle to weld it on I live in Maine so just about everything is surface rusted to shit

 

No leaks for $50. No noise, tight, new brake drums and shoes.