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2003 v8 4x4 diff box/rear axel repairs

Discussion in '1st Gen Tundras (2000-2006)' started by Bradgical, Sep 9, 2022.

  1. Sep 9, 2022 at 8:43 AM
    #1
    Bradgical

    Bradgical [OP] New Member

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    2003 Tundra v8 4x4
    The seal between the drive shaft and diff box gave on the freeway. Locked up the rear axel. Drive shaft is fine. I can't find a used rear axel assembly for the life of me. Is there a chance I would only need to replace the diff box? Advice on finding a diff box and/or rear axel assembly would be wonderful.
    ABS 3.91 ratio.
    Truck located in Columbus, OH.
    20220909_110446[26].jpg
     
    Last edited: Sep 9, 2022
    w666 likes this.
  2. Sep 9, 2022 at 7:01 PM
    #2
    NickB_01TRD

    NickB_01TRD You don't need less cars, just more driveway.

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    I'd say pull out the third member (where all those nuts are) and see what's going on in there to determine what all you need. Never seen this happen before.
     
  3. Sep 9, 2022 at 7:20 PM
    #3
    assassin10000

    assassin10000 New Member

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    Pinion gear snapped. A tooth could have broken off inside and wedged between the gears causing this.

    Get a 3rd member if your housing doesn't have any holes/leaks. Otherwise buy a complete axle housing from a rust free state from somewhere like car-part.com
     
    Jack McCarthy likes this.
  4. Sep 10, 2022 at 8:18 PM
    #4
    KNABORES

    KNABORES Sarcasm incoming

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    2000: Bilstein 5100's 16x8 589's with 265/75/16 and 1.25" spacers Flowmaster 50 series over the axle dump Pioneer touchscreen with backup camera Full interior and dash LED conversion Trailer brake controller with 7 pin Bedliner coat bumpers & trim ARE topper 2019: ARE topper with full Bedrug kit and Vortex rack TRD shifter 1.25" wheel spacers (I like to live dangerously) Red tow hooks for that +15 grip bonus
    Holy barnacles Batman, when was the last time that driveshaft was greased??
     
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  5. Sep 11, 2022 at 3:58 PM
    #5
    Bradgical

    Bradgical [OP] New Member

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    I got all the nuts off with an impact wrench, plenty of wd40, and patient elbow grease with a hammer and wrench. Ugh. But, I am having trouble pulling the the third member off.20220911_184708.jpg
     
  6. Sep 11, 2022 at 4:03 PM
    #6
    Bradgical

    Bradgical [OP] New Member

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    I could not find a rear axel assembly. A mechanic friend searched his nationwide parts database. There were only 6 available in the whole country, and none of them have my specs.
     
  7. Sep 11, 2022 at 4:09 PM
    #7
    assassin10000

    assassin10000 New Member

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    Use a jack under the front of the 3rd member to push up and break the seal/connection.
     
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  8. Sep 11, 2022 at 4:27 PM
    #8
    w666

    w666 D. None of the above

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    Are you sure you got all the bolts?
    3rd.jpg
     
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  9. Sep 11, 2022 at 4:28 PM
    #9
    w666

    w666 D. None of the above

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    Try car-part-com and yotayard.com
     
  10. Sep 11, 2022 at 4:30 PM
    #10
    w666

    w666 D. None of the above

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    And probably a dumb observation on my part, but I don't see any jack stands under the axle...you did pull the axle shafts from both sides, right?
     
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  11. Sep 11, 2022 at 7:20 PM
    #11
    NickB_01TRD

    NickB_01TRD You don't need less cars, just more driveway.

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    For some reason I always forget you have to do this. Should have mentioned it in my prior post. Gotta pull both axle shafts out at least a little bit. Unhook brake lines and such too.

    These are just nuts that attach to studs in the housing. I bet because of the rust he ended up pulling most the studs out of the housing vs just the nuts off the studs.
     
    Bradgical[OP] likes this.
  12. Sep 12, 2022 at 10:47 AM
    #12
    Aerindel

    Aerindel New Member

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    Looks like he broke most of the studs.
     
  13. Sep 12, 2022 at 2:24 PM
    #13
    Bradgical

    Bradgical [OP] New Member

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    Jack worked great to break the seal. Exactly right about the rust and studs coming out of a few of them. Came back on here, because I got it wiggle loose, but it won't slide off. Then...
    I had no idea about pulling the axel shafts out, lol. I am new to all of this. The most I have ever done is change the lower and upper ball joints in the front. I am trying to learn to do all this by myself to save myself thousands of dollars, be more self-sufficient/well-rounded, and I'd love to do custom work to my vehicles in the future for performance, lifespan, and utility in my work.

    There is a bit of custom work here and there, I just got this truck late last year and am coming upon lots of obstacles with it. The new frame sold me. Despite these issues, I still got a great deal. I believe the frame alone costs twice as much as I paid for it. It was from a rich kid that was getting a brand new Tundra from his dad.
     
    bmf4069, w666 and shifty` like this.
  14. Sep 12, 2022 at 2:31 PM
    #14
    KNABORES

    KNABORES Sarcasm incoming

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    Pro tip - get a FSM or Haynes / Chilton’s manual. Also, YouTube university. You have to watch several YouTube videos and then compare against the manual to get a good idea of tools involved and best process. Doing the work yourself can save $$$. Be aware that some of that money saved will be spent on new tools to do the job right. My favorite part. Also know your limitations. AC work, Transmissions, and more complex motor repairs may be best left to the pros. Great job diving in there and good luck with this project!
     
  15. Sep 12, 2022 at 2:41 PM
    #15
    shifty`

    shifty` The Second Shortcoming of Christ

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    This is killer advice, summed up way more briefly than I know how.

    The one warning I'd issue is on the part I bolded in his quote. The underlined part is emphasized on purpose: You're going to find videos on YouTube that are just straight-up full of shit, bad advice, or stuff you should not do. Three out of five videos I checked out just to see what I was in store for when doing valve cover gaskets on a 2UZ were absolutely full of shit, skipping steps, skipping entire gaskets, not using FIPG to seal corners, etc. Always compare to Haynes, Chilton, or FSM.

    I'm not a professional mechanic, but I'm a a seasoned one with a good 3-4 decades of hands-on experience. Even *I* use YouTube before pulling out a single tool or shop towel just to see the motions if it's something I've never done with a specific make/model/drivetrain, or if I may need a refresher, my brain is getting old. With the wealth of hands-on knowledge there, you'd either be adventurous, cocky, or dumb not to. :rofl:
     
  16. Sep 12, 2022 at 2:44 PM
    #16
    Bradgical

    Bradgical [OP] New Member

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    Thanks for the sources. Yes, loving the new tools I am acquiring. Doing the ball joints myself bought me a nice impact wrench with any socket I would need (plus that damn tuning fork, hah). Even after buying tools, I saved hundreds.
     
    KNABORES[QUOTED] likes this.
  17. Sep 12, 2022 at 4:54 PM
    #17
    w666

    w666 D. None of the above

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  18. Sep 12, 2022 at 7:12 PM
    #18
    NickB_01TRD

    NickB_01TRD You don't need less cars, just more driveway.

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    The studs can just unscrew. When we put a new axle housing in my girlfriends dads 01 the only thing that wasn't purchased was new studs. Just pulled the old ones out and reused.
     
  19. Sep 12, 2022 at 7:52 PM
    #19
    Aerindel

    Aerindel New Member

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    I know, but look at the picture, there appears to be broken stud in most of those holes.Screen Shot 2022-09-12 at 8.53.08 PM.jpg

    Screen Shot 2022-09-12 at 8.53.14 PM.jpg
    Screen Shot 2022-09-12 at 8.53.21 PM.jpg
     
  20. Sep 12, 2022 at 7:55 PM
    #20
    shifty`

    shifty` The Second Shortcoming of Christ

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    Once the tailpiece comes off, there'll be a good 3/6" of bolt to latch onto for turning out, though. A little heat, some Kroil or PB, maybe any of the number of bolt extraction kits on the market, and they'll come out.
     
  21. Sep 12, 2022 at 7:58 PM
    #21
    shifty`

    shifty` The Second Shortcoming of Christ

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    PS - I like the ABN stud extractor kit for sale on scAmazon. Can't beat the price, and it actually works pretty well the two times I've used mine so far.
     
  22. Sep 12, 2022 at 8:23 PM
    #22
    NickB_01TRD

    NickB_01TRD You don't need less cars, just more driveway.

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    I see. Fair enough :)
     
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  23. Sep 13, 2022 at 4:09 AM
    #23
    Tundra2

    Tundra2 Zoinked

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    Field service manual is in my signature. @Bradgical if you're viewing this on mobile, turn your phone horizontal to see the signature. You can download it, and then search for keywords on iI.
     
  24. Sep 13, 2022 at 8:06 AM
    #24
    Bradgical

    Bradgical [OP] New Member

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    Thanks guys! Yes, I already found the fsm, and some decent youtube videos to get a better visual of it and some extra info on what to look out for and technique with physically pulling it out/putting a new one in. None of the studs broke, they just unscrewed from the housing.
     

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