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Leaking rear diff

Discussion in '2nd Gen Tundras (2007-2013)' started by TractorDude, Apr 18, 2024.

  1. Apr 18, 2024 at 8:48 AM
    #1
    TractorDude

    TractorDude [OP] New Member

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    Hi All,

    I have been looking through the forum and found some info on the first Gen tundra but could not locate much on the second Gen. My rear diff cover is leaking on my 2010 2wd 4.6l tundra. When searching for new weld on covers I could only find ones made for the first Gen up to 2006. What are the options to get this fixed? Are there weld on diff covers available for the second Gen tundra ? I see can buy the whole axle housing for $1500 but that is an expensive route!
     
  2. Apr 18, 2024 at 9:07 AM
    #2
    TILLY

    TILLY Gently Used Member

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    Is it rusted through? Haven't seen any like that on the 2nd gen here. Got any pics?
     
  3. Apr 18, 2024 at 9:17 AM
    #3
    TractorDude

    TractorDude [OP] New Member

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    Crazy rusty
     
  4. Apr 18, 2024 at 9:18 AM
    #4
    texasrho83

    texasrho83 DGAF#1

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    :eek:
     
    brodesiansneverdie likes this.
  5. Apr 18, 2024 at 9:24 AM
    #5
    TractorDude

    TractorDude [OP] New Member

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    I can't get the filler bolt out either to check the level. Tried this morning. It's become one with the axle housing. First used a 24mm socket and breaker bar. That rounded the metal instantly. Even going to a chisel and hammer I could not release it. Used a torch to heat it, pb blaster. I have neve encountered something so stubborn and the metal is super soft. Ugh
     
  6. Apr 18, 2024 at 9:36 AM
    #6
    texasrho83

    texasrho83 DGAF#1

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    Time to head to the junk yard and scrounge up another axle
     
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  7. Apr 18, 2024 at 9:39 AM
    #7
    NickB_01TRD

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

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  8. Apr 19, 2024 at 8:41 PM
    #8
    Dr_Al

    Dr_Al New Member

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    I made one for my 1st gen Tundra when it rusted through. The rear cover is very thin metal. I just used a 4 1/2" grinder with a cut off wheel to remove the thin rusted metal. Then I just used some 1/8" flat bar (maybe 2" wide) and bent it by hand to fit around the rear diff. Then I used some diamond plate steel for the cover. I welded a 1" steel (not cat iron) female coupler that I cut in half so I could fill the diff. A 1" plug makes for lots of room to fill the axle up and see how close it is to full. It wasn't perfect but it was pretty easy to do. But I have a 2 post lift in my garage so I wasn't on my back. Much easier than trying to find an axle that wasn't rusted.
     
  9. May 24, 2024 at 11:54 AM
    #9
    TractorDude

    TractorDude [OP] New Member

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    Well, thanks for all the advice! Just to circle back and help out anyone else that might have the same issue with a second Gen Tundra. The Dorman cover linked by NickB above (made for the first Gen tundra) is not quite the right size. We used a combination of Nick's advice and Dr_AL. So a collar was welded on the Gen 1 cover to give the clearance then that was used for the repair. 20240524_153835.jpg
     
    Half Assed, bfunke and texasrho83 like this.
  10. May 24, 2024 at 11:57 AM
    #10
    texasrho83

    texasrho83 DGAF#1

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    Interesting fix. Does it utilize OEM fluid volume or do you need less/more?
     
  11. May 24, 2024 at 12:02 PM
    #11
    TractorDude

    TractorDude [OP] New Member

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    It used about half a litre more fluid. It was such a pain.. for everyone who has a second Gen Tundra the same age - go and spray it with some type of rust protection ! I wish I had.
     
    texasrho83 likes this.
  12. May 24, 2024 at 12:21 PM
    #12
    texasrho83

    texasrho83 DGAF#1

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    I routinely wire brush off any scale I find and hit it with rust inhibitor paint.
     

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