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Rusted leaking rear differential cover

Discussion in '1st Gen Tundras (2000-2006)' started by Big Paully, Jun 24, 2018.

  1. Oct 25, 2019 at 7:30 PM
    #31
    Mytechguyri

    Mytechguyri New Member

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    It was... Only thing that sucked was i had to do it twice... Salvager i got first one from miscategorized it as access cab... Turned out it was for double cab.... Bolted right up perfect...but when i slid the axles in i realized i had a problem.... Wouldnt engage the diff... Double cab has a 2" wider wheelbase, so my axles were 1" too short..... So found another in good shape, also for $350 shipped, this time it did come off an access or regular cab so fit perfect...6 hours later was driving it home.... So now i have a double cab housing i don't need.
     
  2. Oct 30, 2019 at 8:01 PM
    #32
    Jordanct1

    Jordanct1 New Member

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    Hey I might be able to use that. Let me know if you still have it. I have a 2004 tundra double cab 4x4 with abs. I'm in CT and I'm assuming you are in RI. I am dealing with this same issue and don't want to spend a fortune to fix it.
     
    Mytechguyri and NUDRAT like this.
  3. Oct 31, 2019 at 7:41 PM
    #33
    Mytechguyri

    Mytechguyri New Member

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    Yup still got it....
     
  4. Nov 4, 2019 at 6:26 PM
    #34
    Oldgray

    Oldgray New Member

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    Where are you located?
     
  5. May 22, 2020 at 8:47 AM
    #35
    Deverett5

    Deverett5 New Member

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    I know this is a late post on this topic but would a rear from a 2003 tundra with ABS be able go into a 2001 tundra that doesn't have ABS has the same gears and everything?
     
  6. May 22, 2020 at 9:01 AM
    #36
    empty_lord

    empty_lord They see me rollin'

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    custom body work, Billies with taco ARB springs, Icon AAL, TRD FJ trail team wheels, 2019 Toyota 86 radio, Blacked out interior, Added factory power everything, heater mirrors, ETC
    Yes. You just need to snip
    Off the wires from the abs sensors and leave the sensors in to plug the holes
     
    NUDRAT and Deverett5[QUOTED] like this.
  7. Jun 3, 2020 at 5:47 PM
    #37
    Jeffersonjohn

    Jeffersonjohn New Member

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    So my rear differential is leaking worse. I'm a machinist, not a welder. Has anybody tried grinding off the old cover and drilling and tapping a series of holes around it and sealing it with silicone gasket in a tube?
     
  8. Jun 3, 2020 at 6:06 PM
    #38
    Professional Hand Model

    Professional Hand Model A.K.A ‘Golden Hands’

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    No but it sounds doable for someone with your skills. You’d be a hero to all those that have done the other routes (JB Weld, etc).
     
  9. Jun 4, 2020 at 10:28 AM
    #39
    Festerw

    Festerw New Member

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    Should work but seems more labor intensive than just using something like this.
    https://www.amazon.com/Loctite-Bonding-Compound-2-Fluid-1360700/dp/B0044F9JWM
     
  10. Jun 5, 2020 at 8:54 AM
    #40
    delz05

    delz05 Old relic... Living and Loving Life!!!

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    Work in progress...
    Why not just go the "new cover" route... barnes4wd.com
     
  11. Jun 13, 2020 at 8:40 AM
    #41
    Jeffersonjohn

    Jeffersonjohn New Member

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    I drilled and tapped 8 1/4-20 holes and sealed the new one with silicone gasket. I'll see how it works out. Thanks for the advice all.
     
  12. Jun 13, 2020 at 9:15 AM
    #42
    tvpierce

    tvpierce Formerly New Member

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    What cover did you use?
     
  13. Jun 13, 2020 at 12:40 PM
    #43
    Professional Hand Model

    Professional Hand Model A.K.A ‘Golden Hands’

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    Hand Protectors
    Post up some pics man!
     
  14. Jun 13, 2020 at 3:02 PM
    #44
    Jeffersonjohn

    Jeffersonjohn New Member

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  15. Jun 13, 2020 at 3:03 PM
    #45
    Jeffersonjohn

    Jeffersonjohn New Member

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  16. Jun 13, 2020 at 3:14 PM
    #46
    Jeffersonjohn

    Jeffersonjohn New Member

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    Looks like I posted three of the same pic.
    If you want a step by step I'll write it out when I get time. This took up all my free time for a week and I'm behind on chores.
     
  17. Jun 13, 2020 at 5:29 PM
    #47
    Professional Hand Model

    Professional Hand Model A.K.A ‘Golden Hands’

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    @Darkness

    This green would match your spare tire.
     
    YardBird likes this.
  18. Jun 13, 2020 at 6:26 PM
    #48
    Pucks18

    Pucks18 Fleabit peanut monkey

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    Anyone have good tips for buying a used rear axle? Like can a 2x4 axle hook up to a 4x4? Can a 2005 access cab go into a 2001 access cab? And whats the best website to look for one at? Thanks
     
  19. Aug 11, 2020 at 6:12 AM
    #49
    ibiggs22

    ibiggs22 New Member

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    So I had this issue, my rear differential was leaking on the drivers side of the cover. It was a slow leak, about a drop an hour but I wanted to get ahead of the situation. I followed Big Paully's advice and it has not leaked in over 500 miles of driving it. Not the prettiest but it works for sure.

    1.jpg 2.jpg 3.jpg 4.jpg
     
  20. Aug 11, 2020 at 4:26 PM
    #50
    N84434

    N84434 In the Frozen Tundra

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    Nice work. Make sure the vent on top of the differential housing is open and able to breath. Keeps pressure down inside the diff...
     
  21. Aug 12, 2020 at 5:47 AM
    #51
    ibiggs22

    ibiggs22 New Member

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    Yep, made sure the breather was clean and clear!
     
  22. Aug 12, 2020 at 6:26 AM
    #52
    Pucks18

    Pucks18 Fleabit peanut monkey

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    What did you use? Very curious
     
  23. Aug 12, 2020 at 7:24 AM
    #53
    ibiggs22

    ibiggs22 New Member

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    Follow the initial post in this tread from Big Paully.
    1. Pour 15 kit: degreaser, metal prep, then Pour 15 (4 coats) PS. wear freaking gloves with pour 15. That stuff will stain your hands like nothing else.
    2. Flex seal around the weld seam.
    3. 2 or 3 coats of truck bed liner.

    Took about 2.5 days because of the time it took to dry between coats. If I can do it, anyone can do it.
     
  24. Aug 14, 2020 at 7:04 AM
    #54
    Jimbobber10

    Jimbobber10 New Member

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    Just did this job myself. Opted to replace the cover with a Dorman new one.
    1st mistake,, YOU HAVE TO GAS WELD (not electric) to retain fluid! Our 'welder buddy' used electric to booger weld it and it kept leaking and had to be re welded by a good welder with Gas.
    'While in there', I replaced the rusted backing plates, which means pulling the axles, which means do the wheel bearing, seals, etc 'when you're in there'.
    Warning, don't be fooled by the YouTube videos where these guys pop out the bearings just by banging them on the ground. Be prepared to torch them out! 2 different 20 ton harbor freight presses wouldn't budge them.
    Turned in to a 3 day hell job that saved me about $1500 over replacing the entire housing with a new housing. A used housing, shipped, off ebay would have cost me $1000- and who knows what shape the bearings in those are.
     
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  25. Aug 22, 2020 at 6:50 PM
    #55
    TUNDRA_

    TUNDRA_ New Member

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    Please share the steps you took to complete this project. I have been thinking of doing this bolt on cover for about 3 years but never really did it. Excellent work on your part!!

    Please mention how difficult grinding the old cover was. Did you first cut it above the weld line and then grind it down? How did you achieve a flat surface.

    I think your idea and execution is the best out there so far. How is it holding up and how many miles have you driven after?

    thank you.
     
  26. Aug 22, 2020 at 6:52 PM
    #56
    TUNDRA_

    TUNDRA_ New Member

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    Forgot to add?
    How wide is the lip on the new cover? Is it enough to seal or do you think they should make one with a wider lip.

    tia
     
  27. Sep 30, 2020 at 11:00 AM
    #57
    Mdovey86

    Mdovey86 New Member

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    I’m having issues with my 02 3.4l 2WD leaking. I tried the POR15 route. Did not work.
    So I have to find a rear end for my exact model? Can I use a rear end from a 4WD tundra?
     
    Pucks18 likes this.
  28. Sep 30, 2020 at 2:29 PM
    #58
    Kongap

    Kongap New Member

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    Did you try sanding and jb weld?
     
    N84434 likes this.
  29. Sep 30, 2020 at 4:08 PM
    #59
    N84434

    N84434 In the Frozen Tundra

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    When I started cleaning all the rust off mine, it started to drip from a rust perforation, so I drained the differential, cleaned the area thoroughly, sealed it with Black Form-A-Gasket, painted it with my rust stop paint (Chassis Saver) and then added a second layer of the Form-A-Gasket. Has not leaked at all..... At all.

    Maybe try a good quality gasket sealer and then paint??
     
  30. Sep 30, 2020 at 4:21 PM
    #60
    Kongap

    Kongap New Member

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    don’t forget to make sure your breather is working!
     

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