1. Welcome to Tundras.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tundra discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other Tundra owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site
    Quick Links: What is an inexpesive way to connect these cut wires? Can anyone help me diagnose this leak under the drivers side axle? I'm trying to install a zero start 1500w coolant heater to my 05 tundra, Why Is My Front Diff Breather Venting Gear Oil? Replacing timing belt&water pump, what else while I'm in there? Would you do it ?

Rusted leaking rear differential cover

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

Page 2 of 5
  1. Oct 25, 2019 at 7:30 PM
    #31
    Mytechguyri

    #31
    Mytechguyri New Member

    Joined:
    Dec 6, 2018
    Member:
    #22676
    Messages:
    22
    Gender:
    Male
    First Name:
    John
    Vehicle:
    2004 Tundra 4x4 Access Cab step side
    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.
     
    Mytechguyri, Oct 25, 2019
    #31
  2. Oct 30, 2019 at 8:01 PM
    #32
    Jordanct1

    #32
    Jordanct1 New Member

    Joined:
    Oct 30, 2019
    Member:
    #38064
    Messages:
    1
    Gender:
    Male
    Vehicle:
    2004 double cab 4x4
    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.
     
    Jordanct1, Oct 30, 2019
    #32
    Mytechguyri and NUDRAT like this.
  3. Oct 31, 2019 at 7:41 PM
    #33
    Mytechguyri

    #33
    Mytechguyri New Member

    Joined:
    Dec 6, 2018
    Member:
    #22676
    Messages:
    22
    Gender:
    Male
    First Name:
    John
    Vehicle:
    2004 Tundra 4x4 Access Cab step side
    Yup still got it....
     
    Mytechguyri, Oct 31, 2019
    #33
  4. Nov 4, 2019 at 6:26 PM
    #34
    Oldgray

    #34
    Oldgray New Member

    Joined:
    Oct 13, 2019
    Member:
    #37351
    Messages:
    14
    Gender:
    Male
    First Name:
    Lee
    Vehicle:
    Double cab limited
    Where are you located?
     
    Oldgray, Nov 4, 2019
    #34
  5. May 22, 2020 at 8:47 AM
    #35
    Deverett5

    #35
    Deverett5 New Member

    Joined:
    May 12, 2020
    Member:
    #46460
    Messages:
    13
    Gender:
    Male
    First Name:
    Dakota
    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?
     
    Deverett5, May 22, 2020
    #35
  6. May 22, 2020 at 9:01 AM
    #36
    empty_lord

    #36
    empty_lord They see me rollin'

    Joined:
    Feb 1, 2019
    Member:
    #25441
    Messages:
    10,146
    Gender:
    Male
    First Name:
    Dan
    Indiana, Chicagoland
    Vehicle:
    05 rollover special
    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
     
    empty_lord, May 22, 2020
    #36
    NUDRAT and Deverett5[QUOTED] like this.
  7. Jun 3, 2020 at 5:47 PM
    #37
    Jeffersonjohn

    #37
    Jeffersonjohn New Member

    Joined:
    Jun 3, 2020
    Member:
    #47498
    Messages:
    6
    Gender:
    Male
    Vehicle:
    04 Sequoia
    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?
     
    Jeffersonjohn, Jun 3, 2020
    #37
  8. Jun 3, 2020 at 6:06 PM
    #38
    Professional Hand Model

    #38
    Professional Hand Model A.K.A ‘Golden Hands’

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    14,993
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    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).
     
    Professional Hand Model, Jun 3, 2020
    #38
  9. Jun 4, 2020 at 10:28 AM
    #39
    Festerw

    #39
    Festerw New Member

    Joined:
    May 7, 2017
    Member:
    #7600
    Messages:
    3,881
    Gender:
    Male
    Cambridge Springs, PA
    Vehicle:
    04 Tundra DC
    Should work but seems more labor intensive than just using something like this.
    Epoxy Weld Bonding Compound Adhesive System, 1 Tube of Hardener, 1 Tube of Resin
    https://www.amazon.com/Loctite-Bonding-Compound-2-Fluid-1360700/dp/B0044F9JWM
     
    Festerw, Jun 4, 2020
    #39
  10. Jun 5, 2020 at 8:54 AM
    #40
    delz05

    #40
    delz05 Old relic... Living and Loving Life!!!

    Joined:
    Jun 8, 2015
    Member:
    #1393
    Messages:
    123
    Gender:
    Male
    BOSTON
    Vehicle:
    2005 Tundra Limited
    Work in progress...
    Why not just go the "new cover" route... barnes4wd.com
     
    delz05, Jun 5, 2020
    #40
  11. Jun 13, 2020 at 8:40 AM
    #41
    Jeffersonjohn

    #41
    Jeffersonjohn New Member

    Joined:
    Jun 3, 2020
    Member:
    #47498
    Messages:
    6
    Gender:
    Male
    Vehicle:
    04 Sequoia
    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.
     
    Jeffersonjohn, Jun 13, 2020
    #41
    CDTundrafool, YardBird and Professional Hand Model like this.
  12. Jun 13, 2020 at 9:15 AM
    #42
    tvpierce

    #42
    tvpierce Formerly New Member

    Joined:
    May 6, 2019
    Member:
    #30129
    Messages:
    1,488
    Maine
    Vehicle:
    2000 Tundra AC SR5 4WD, 4.7 Automatic
    What cover did you use?
     
    tvpierce, Jun 13, 2020
    #42
  13. Jun 13, 2020 at 12:40 PM
    #43
    Professional Hand Model

    #43
    Professional Hand Model A.K.A ‘Golden Hands’

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    14,993
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    Post up some pics man!
     
    Professional Hand Model, Jun 13, 2020
    #43
  14. Jun 13, 2020 at 3:02 PM
    #44
    Jeffersonjohn

    #44
    Jeffersonjohn New Member

    Joined:
    Jun 3, 2020
    Member:
    #47498
    Messages:
    6
    Gender:
    Male
    Vehicle:
    04 Sequoia
    15920855268623319272866995935785.jpg 15920855268623319272866995935785.jpg 15920855268623319272866995935785.jpg
     
    Jeffersonjohn, Jun 13, 2020
    #44
    KamperBob, tvpierce, NUDRAT and 3 others like this.
  15. Jun 13, 2020 at 3:03 PM
    #45
    Jeffersonjohn

    #45
    Jeffersonjohn New Member

    Joined:
    Jun 3, 2020
    Member:
    #47498
    Messages:
    6
    Gender:
    Male
    Vehicle:
    04 Sequoia
    The Dorman cover
     
    Jeffersonjohn, Jun 13, 2020
    #45
    Jack McCarthy, YardBird and Professional Hand Model like this.
  16. Jun 13, 2020 at 3:14 PM
    #46
    Jeffersonjohn

    #46
    Jeffersonjohn New Member

    Joined:
    Jun 3, 2020
    Member:
    #47498
    Messages:
    6
    Gender:
    Male
    Vehicle:
    04 Sequoia
    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.
     
    Jeffersonjohn, Jun 13, 2020
    #46
  17. Jun 13, 2020 at 5:29 PM
    #47
    Professional Hand Model

    #47
    Professional Hand Model A.K.A ‘Golden Hands’

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    14,993
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    @Darkness

    This green would match your spare tire.
     
    Professional Hand Model, Jun 13, 2020
    #47
    YardBird likes this.
  18. Jun 13, 2020 at 6:26 PM
    #48
    Pucks18

    #48
    Pucks18 Fleabit peanut monkey

    Joined:
    Jan 21, 2020
    Member:
    #41548
    Messages:
    1,171
    Gender:
    Male
    Vehicle:
    2001 Tundra 4x4 Limited trd
    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
     
    Pucks18, Jun 13, 2020
    #48
  19. Aug 11, 2020 at 6:12 AM
    #49
    ibiggs22

    #49
    ibiggs22 New Member

    Joined:
    Dec 10, 2019
    Member:
    #39736
    Messages:
    6
    Gender:
    Male
    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
     
    ibiggs22, Aug 11, 2020
    #49
    ktundra, bmf4069, Professional Hand Model and 1 other person like this.
  20. Aug 11, 2020 at 4:26 PM
    #50
    N84434

    #50
    N84434 In the Frozen Tundra

    Joined:
    Jan 22, 2020
    Member:
    #41580
    Messages:
    1,087
    Gender:
    Male
    First Name:
    Jim
    Milwaukee WI.
    Vehicle:
    2001 Limited TRD
    Nice work. Make sure the vent on top of the differential housing is open and able to breath. Keeps pressure down inside the diff...
     
    N84434, Aug 11, 2020
    #50
    KamperBob, bmf4069, NUDRAT and 1 other person like this.
  21. Aug 12, 2020 at 5:47 AM
    #51
    ibiggs22

    #51
    ibiggs22 New Member

    Joined:
    Dec 10, 2019
    Member:
    #39736
    Messages:
    6
    Gender:
    Male
    Yep, made sure the breather was clean and clear!
     
    ibiggs22, Aug 12, 2020
    #51
    KamperBob, bmf4069, N84434[QUOTED] and 1 other person like this.
  22. Aug 12, 2020 at 6:26 AM
    #52
    Pucks18

    #52
    Pucks18 Fleabit peanut monkey

    Joined:
    Jan 21, 2020
    Member:
    #41548
    Messages:
    1,171
    Gender:
    Male
    Vehicle:
    2001 Tundra 4x4 Limited trd
    What did you use? Very curious
     
    Pucks18, Aug 12, 2020
    #52
  23. Aug 12, 2020 at 7:24 AM
    #53
    ibiggs22

    #53
    ibiggs22 New Member

    Joined:
    Dec 10, 2019
    Member:
    #39736
    Messages:
    6
    Gender:
    Male
    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.
     
    ibiggs22, Aug 12, 2020
    #53
    N84434, bmf4069 and Professional Hand Model like this.
  24. Aug 14, 2020 at 7:04 AM
    #54
    Jimbobber10

    #54
    Jimbobber10 New Member

    Joined:
    Sep 5, 2018
    Member:
    #19061
    Messages:
    6
    Gender:
    Male
    Vehicle:
    2000 V8 4.7L
    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.
     
    This site contains affiliate links for which the site may be compensated.
    Jimbobber10, Aug 14, 2020
    #54
    The Black Mamba, ktundra, bmf4069 and 2 others like this.
  25. Aug 22, 2020 at 6:50 PM
    #55
    TUNDRA_

    #55
    TUNDRA_ New Member

    Joined:
    Apr 25, 2018
    Member:
    #14747
    Messages:
    2
    Vehicle:
    2000 Tundra 4.7 4WD
    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.
     
    TUNDRA_, Aug 22, 2020
    #55
  26. Aug 22, 2020 at 6:52 PM
    #56
    TUNDRA_

    #56
    TUNDRA_ New Member

    Joined:
    Apr 25, 2018
    Member:
    #14747
    Messages:
    2
    Vehicle:
    2000 Tundra 4.7 4WD
    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
     
    TUNDRA_, Aug 22, 2020
    #56
  27. Sep 30, 2020 at 11:00 AM
    #57
    Mdovey86

    #57
    Mdovey86 New Member

    Joined:
    Sep 30, 2020
    Member:
    #52977
    Messages:
    7
    Gender:
    Male
    First Name:
    Matt
    Vehicle:
    2002 Tundra SR5
    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?
     
    Mdovey86, Sep 30, 2020
    #57
    Pucks18 likes this.
  28. Sep 30, 2020 at 2:29 PM
    #58
    Kongap

    #58
    Kongap New Member

    Joined:
    Sep 24, 2020
    Member:
    #52716
    Messages:
    91
    Vehicle:
    2004 SR5 DC
    Did you try sanding and jb weld?
     
    Kongap, Sep 30, 2020
    #58
    N84434 likes this.
  29. Sep 30, 2020 at 4:08 PM
    #59
    N84434

    #59
    N84434 In the Frozen Tundra

    Joined:
    Jan 22, 2020
    Member:
    #41580
    Messages:
    1,087
    Gender:
    Male
    First Name:
    Jim
    Milwaukee WI.
    Vehicle:
    2001 Limited TRD
    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??
     
    N84434, Sep 30, 2020
    #59
    Professional Hand Model and Kongap like this.
  30. Sep 30, 2020 at 4:21 PM
    #60
    Kongap

    #60
    Kongap New Member

    Joined:
    Sep 24, 2020
    Member:
    #52716
    Messages:
    91
    Vehicle:
    2004 SR5 DC
    don’t forget to make sure your breather is working!
     
    Kongap, Sep 30, 2020
    #60
    KamperBob, Glock 40, NUDRAT and 1 other person like this.
Page 2 of 5
Register FREE to Reply!

Products Discussed in

Dorman 926-958 Rear Differential Cover Compatible with Select Toyota Models (OE FIX)
$62.63
To Top