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

Rusted leaking rear differential cover

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

  1. Sep 30, 2020 at 4:48 PM
    #61
    N84434

    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
    Good point... mine was all clogged up and rusty, so I removed the check valve and spring and put a section of hose on it with a worm clamp, and attached The other end to the frame. Kind of like a snorkel, but not really....
     
  2. Oct 6, 2020 at 7:24 AM
    #62
    HanD

    HanD New Member

    Joined:
    Oct 2, 2020
    Member:
    #53052
    Messages:
    29
    Gender:
    Male
    Maryland
    Vehicle:
    05 DC
    did you find anyone to weld it for you? i just had mine done in Gaithersburg.
     
  3. Oct 6, 2020 at 7:31 AM
    #63
    Kongap

    Kongap New Member

    Joined:
    Sep 24, 2020
    Member:
    #52716
    Messages:
    91
    Vehicle:
    2004 SR5 DC
    Did you strip it down?
     
  4. Oct 6, 2020 at 7:33 AM
    #64
    HanD

    HanD New Member

    Joined:
    Oct 2, 2020
    Member:
    #53052
    Messages:
    29
    Gender:
    Male
    Maryland
    Vehicle:
    05 DC
    which flex seal product did you use?


    i had a shop weld the new cover from barnes4wd
     
  5. Oct 6, 2020 at 8:05 AM
    #65
    Kongap

    Kongap New Member

    Joined:
    Sep 24, 2020
    Member:
    #52716
    Messages:
    91
    Vehicle:
    2004 SR5 DC
    Right. I’m asking if you tore it down or if they did? How much was it?
     
  6. Oct 6, 2020 at 8:08 AM
    #66
    HanD

    HanD New Member

    Joined:
    Oct 2, 2020
    Member:
    #53052
    Messages:
    29
    Gender:
    Male
    Maryland
    Vehicle:
    05 DC
    sorry for misunderstanding. They did all the work. Cut the old one off and welded the new one. I paid 350 for labor but he way underestimated the job. it took him a lot longer than he had expected. he honored the quote though.
     
    Pucks18 likes this.
  7. Oct 6, 2020 at 9:59 AM
    #67
    Kongap

    Kongap New Member

    Joined:
    Sep 24, 2020
    Member:
    #52716
    Messages:
    91
    Vehicle:
    2004 SR5 DC
    No worries. Good deal, it seems like a lot of work!
     
  8. Feb 28, 2021 at 6:16 AM
    #68
    KamperBob

    KamperBob New Member

    Joined:
    Feb 28, 2021
    Member:
    #59746
    Messages:
    13
    Gender:
    Male
    Vehicle:
    2002 Tundra Limited 4WD 4.7L
    Special thanks to NUDRAT for sharing the breather tip! While a new "axle vent" is only ~ten bux (Dorman 924-262) I just cleaned mine. Just pried the dust cap off, scraped out the crud, then crimped the cap back over the flange. Easy peasy.

    I think the clogged vent observation is KEY. My rust leak is on the bottom. Seems like pix from others was too. Pondering that for a spell it makes sense. With vent clogged any moisture (condensation) trapped inside the housing could settle under hot oil on bottom. (Oil is lighter than water.) Corrosion can work inside out. So it makes sense to check the vent periodically.

    I just ordered a new cover and some Permatex 81182 Gear Oil RTV Gasket Maker. Special thanks to Jeffersonjohn for sharing to bolt-conversion cover. I plan to clone that solution next weekend after the stuff I ordered arrives. I can follow up afterwards. Meanwhile, I'll try sharing a couple pix of my leak: first dirty; then cleaned to find culprit.

    DiffLeak-Dirty.jpg DiffLeak-Cleaned.jpg

    PS- My 02 Tundra spent its first 8 winters in snow/salt states. It currently has 273k miles.
     
    Filthyphil, Pucks18 and NUDRAT like this.
  9. Feb 28, 2021 at 6:23 AM
    #69
    KamperBob

    KamperBob New Member

    Joined:
    Feb 28, 2021
    Member:
    #59746
    Messages:
    13
    Gender:
    Male
    Vehicle:
    2002 Tundra Limited 4WD 4.7L
    Oh, and that first pic is a bit misleading. Mine did NOT leak around the fill plug. Checking the level first I dragged some oil out the opening with my finger before pix.
     
  10. Feb 28, 2021 at 6:33 AM
    #70
    NUDRAT

    NUDRAT 6 lug life

    Joined:
    Dec 7, 2018
    Member:
    #22736
    Messages:
    3,054
    Gender:
    Male
    SW CT
    Vehicle:
    off-brand 1st Gen
    I expect if you were to remove that scale on the bottom you wouldn't find a long crack/leak, rather a pin hole or two.
     
  11. Feb 28, 2021 at 7:40 AM
    #71
    KamperBob

    KamperBob New Member

    Joined:
    Feb 28, 2021
    Member:
    #59746
    Messages:
    13
    Gender:
    Male
    Vehicle:
    2002 Tundra Limited 4WD 4.7L
    Agreed. I know it looks like a possible crack in that pic, but I only scratched the loose scale off with a wire brush by hand. My goal at the time was just clean enough to find the leak. I suspect that line in the pic is, mostly at least, just the edge of scale over the cover that didn't come off. Still, that scale could be hiding/holding more perforation. Following repair I plan to autopsy the OEM cover to see if my theory of internal corrosion holds water. Sorry 'bout that pun.
     
  12. Feb 28, 2021 at 7:58 AM
    #72
    Professional Hand Model

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

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    15,007
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    Keep posting pics of your work. We like pics.
     
    Pucks18 and KamperBob[QUOTED] like this.
  13. Feb 28, 2021 at 8:28 AM
    #73
    Jack McCarthy

    Jack McCarthy Truck repair enthusiast; Rust Aficionado

    Joined:
    Nov 2, 2020
    Member:
    #54409
    Messages:
    7,729
    Gender:
    Male
    First Name:
    Bill
    North of Boston
    Vehicle:
    02 Tundra AC SR5 V8 4x4
    Wow. I’m a firm believer in POR-15 but I never heard of it being used to stop leaks in addition to the spread of rust. I’m not sure if that was it’s intended application. lol
     
    Pucks18 and NUDRAT like this.
  14. Feb 28, 2021 at 8:33 AM
    #74
    Professional Hand Model

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

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    15,007
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    As mentioned the Jeffersonjon Dorman Cover Fix looks solid. That would be how I’d approach the fix if in the same boat. Probably less time to fix and slightly more money. Looks solid.

    upload_2021-2-28_11-32-42.jpg
     
    Pucks18 and NUDRAT like this.
  15. Mar 5, 2021 at 6:59 PM
    #75
    Straussberg

    Straussberg New Member

    Joined:
    Aug 7, 2020
    Member:
    #50459
    Messages:
    15
    Gender:
    Male
    First Name:
    Anthony
    Vehicle:
    2003 Toyota Tundra SR5
    So, I’ve got to do this patch this weekend on my sequoia... already have the bleed valve coming tomorrow. So let me make sure I know the proper order.
    1. Verify the drain/fill bolts are releasable, top, then bottom
    2. Remove rust scale with wire brush/wheel
    3. Replace the diff case bleed valve
    4. Drain the case
    5. Identify pinholes if any
    6. Clean the whole thing with brake cleaner
    7. Prep and apply POR 15 first coat
    8. JB Weld it like a birthday cake?
    9. Apply as many more coats of POR 15 as the little can allows
    10. Refill the diff case and pray something else doesn’t go wrong with this Godforsaken rust bucket before I can buy a replacement rear axle assembly.

    Should I JB weld before or after the POR 15? I know I need to wait at least 12 hours between applications.
     
  16. Mar 6, 2021 at 3:04 AM
    #76
    tvpierce

    tvpierce Formerly New Member

    Joined:
    May 6, 2019
    Member:
    #30129
    Messages:
    1,261
    Maine
    Vehicle:
    2000 Tundra AC SR5 4WD, 4.7 Automatic
    If you're referring to POR-15, that's incorrrect. You want to apply additional coats while it's still slightly tacky -- which will be about 2 hours depending on temperature and humidity. (It actually dries quicker in high humidity)
    If you let it dry 12 hours between coats, you need to sand it to rough it up before applying the next coat.
     
  17. Mar 6, 2021 at 3:09 AM
    #77
    Festerw

    Festerw New Member

    Joined:
    May 7, 2017
    Member:
    #7600
    Messages:
    3,692
    Gender:
    Male
    Cambridge Springs, PA
    Vehicle:
    04 Tundra DC
    I'd do the JB first, you want that stuck to steel not paint.
     
  18. Mar 6, 2021 at 4:04 AM
    #78
    tvpierce

    tvpierce Formerly New Member

    Joined:
    May 6, 2019
    Member:
    #30129
    Messages:
    1,261
    Maine
    Vehicle:
    2000 Tundra AC SR5 4WD, 4.7 Automatic
    I respectfully disagree. POR-15 is specifically made to bond to rust, JB Weld is not and will not.

    @Straussberg : is your diff cover already leaking, or is this a preventive measure?
     
  19. Mar 6, 2021 at 5:10 AM
    #79
    KamperBob

    KamperBob New Member

    Joined:
    Feb 28, 2021
    Member:
    #59746
    Messages:
    13
    Gender:
    Male
    Vehicle:
    2002 Tundra Limited 4WD 4.7L
    While I can't contribute to the JBWeld .vs. POR15 debate, I offer this food for thought. If the rust/scale is not removed down to bare metal then what does it matter how well either product adheres to flakes? Sooner or later flakes must progress/loosen/separate.

    Update on mine. Got the stuff a few days ago. Exploratory revealed difficulties removing the original cover. Decided to book some garage time, remove the whole axle from the truck, safely make sparks. Hopefully that will last the remaining life of the truck. Later this month...
     
    des2mtn likes this.
  20. Mar 6, 2021 at 7:24 AM
    #80
    Festerw

    Festerw New Member

    Joined:
    May 7, 2017
    Member:
    #7600
    Messages:
    3,692
    Gender:
    Male
    Cambridge Springs, PA
    Vehicle:
    04 Tundra DC
    I guess I assumed that he was getting down to bare metal first.

    I'll be honest I've never actually used JB so I'm not sure what it'll adhere to.
     
  21. Mar 6, 2021 at 9:32 AM
    #81
    Pucks18

    Pucks18 Fleabit peanut monkey

    Joined:
    Jan 21, 2020
    Member:
    #41548
    Messages:
    1,171
    Gender:
    Male
    Vehicle:
    2001 Tundra 4x4 Limited trd
    I would personally think you'd want your por15 to adhere to your rusty axle housing like its made to do, then throw some jb weld over the 2nd or 3rd coat of your por. I wouldn't put por15 on jbweld ever but I'd but jb welb on por15
     
  22. Mar 6, 2021 at 9:38 AM
    #82
    Straussberg

    Straussberg New Member

    Joined:
    Aug 7, 2020
    Member:
    #50459
    Messages:
    15
    Gender:
    Male
    First Name:
    Anthony
    Vehicle:
    2003 Toyota Tundra SR5
    Like a sieve... this is from a week ago and it’s gotten worse since.

    AB7A5306-3C61-464F-9EBF-B4D5CA783B4C.jpg
     
    KamperBob likes this.
  23. Mar 6, 2021 at 1:34 PM
    #83
    tvpierce

    tvpierce Formerly New Member

    Joined:
    May 6, 2019
    Member:
    #30129
    Messages:
    1,261
    Maine
    Vehicle:
    2000 Tundra AC SR5 4WD, 4.7 Automatic
    Ouch!

    Clean that up good. Nothing sticks good to grease and oil.
     
  24. Mar 6, 2021 at 6:04 PM
    #84
    assassin10000

    assassin10000 New Member

    Joined:
    Oct 27, 2020
    Member:
    #54157
    Messages:
    1,866
    First Name:
    Andrew
    Northern CA
    Vehicle:
    '05 SR5 AC
    Remote start alarm Removed keyless entry piezo Qi phone charger & dash mount Subaru underseat subwoofer Hopkins Easylift Steering wheel audio controls No-tenna mod 3/4 adhesive anti-rattle shim D/S door
    I'd drain the diff, wire wheel/sand around pinhole(s) for clean metal, jb weld, then por-15 and lastly refill the diff. Jmho.
     
  25. Mar 7, 2021 at 11:33 AM
    #85
    Straussberg

    Straussberg New Member

    Joined:
    Aug 7, 2020
    Member:
    #50459
    Messages:
    15
    Gender:
    Male
    First Name:
    Anthony
    Vehicle:
    2003 Toyota Tundra SR5
    Can I torch the fill bolt to get it off, or is that a bad idea? Good news is the leak isn’t that bad while it’s sitting here, even with literally everything under here covered in oil.

    On a side note, I have no idea how my brakes are still working with the steel feed lines in such poor shape. A132798C-1700-4238-A3FE-C691712A862C.jpg
    E48086C3-34E8-4C1C-905E-D58BB7801363.jpg15C0902F-00DA-470D-A7CB-F59675E7F9F9.jpg
     
    KamperBob likes this.
  26. Mar 8, 2021 at 5:01 AM
    #86
    Richid

    Richid New Member

    Joined:
    Jan 2, 2021
    Member:
    #56976
    Messages:
    168
    Just my .02 - it only took a few hours to swap the axle. It seems like you're spending a lot of time chasing a temporary fix.

    FYI for anyone trying to seal the rust axle housing. Gas tank sealer will only last a couple of weeks, don't bother.

    Good luck, it's kind of shitty that this a weak spot. I bought a used axle from a southern truck, but the dealer quoted me $1200 for new housing, bearings, seals, and gaskets (about 8 years ago).
     
  27. Mar 8, 2021 at 8:59 PM
    #87
    Straussberg

    Straussberg New Member

    Joined:
    Aug 7, 2020
    Member:
    #50459
    Messages:
    15
    Gender:
    Male
    First Name:
    Anthony
    Vehicle:
    2003 Toyota Tundra SR5
    Looks like a new housing is 1100+ by itself. For me, that and the brake lines are next over the next few months; I just don’t have the budget right now for it...

    here she is before the paint and after 3 coats! There’s even a photo of the one clean original painted non rusted spot on this case! Haha!

    thank you again everyone! I’m going to try to get one more coat out of this tiny can and then JB Weld it around where I think it was leaking tomorrow.

    DBFE2E92-7816-408E-BD8D-D68367E5E5A3.jpg ECA1C607-8842-4971-89E8-7C0B8D2D56F1.jpg 2E735FE1-8E4E-4DD7-828E-FB91EAF4C469.jpg CFF91742-C03C-4693-8714-15985012751F.jpg
     
    KamperBob likes this.
  28. Mar 9, 2021 at 6:04 AM
    #88
    Professional Hand Model

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

    Joined:
    Apr 29, 2018
    Member:
    #14878
    Messages:
    15,007
    Gender:
    Male
    First Name:
    Fred
    ‘Somewhere’... a State of Mind
    Vehicle:
    2002 Tundra SR5 4WD 4.7L AC Silver Metallica
    Hand Protectors
    Hope she holds! Def get those brake lines fixed even if you have to borrow money.
     
  29. Mar 10, 2021 at 2:53 AM
    #89
    tvpierce

    tvpierce Formerly New Member

    Joined:
    May 6, 2019
    Member:
    #30129
    Messages:
    1,261
    Maine
    Vehicle:
    2000 Tundra AC SR5 4WD, 4.7 Automatic
    Looks good. Yeah, this whole method is kind of a cobb-job, but if it seals it up (or even slows the leak way down) it's bought you some time and didn't cost too much in time or money.
    Make sure to scuff up the area where you'll be applying JB Weld. I needs some tooth to bond to it.
     
  30. Mar 10, 2021 at 3:55 AM
    #90
    Festerw

    Festerw New Member

    Joined:
    May 7, 2017
    Member:
    #7600
    Messages:
    3,692
    Gender:
    Male
    Cambridge Springs, PA
    Vehicle:
    04 Tundra DC

Products Discussed in

To Top