ok guys, ,my rear cover was leaking bad. typical on these rears to rust out, i had more j.b weld then metal on mine and spending 15 bucks every month on more j,b weld was getting old and i figured this summer if i even tapped a rock it would be total loss so this was my fix im a welder/fabricator so if you try this its on your own risk.
What i used - blue torch fabrications kryptonight rear FJ 40 diff cover you could use a stock fj 40 rear cover if you didn't want a 1/4 inch steel cover this cover had to be modified a little as you can see in picture, i cut the top and bottom flange completely off
BTF Toyota FJ40/LandCruiser Rear Kryptonite Differential Cover :: Blue Torch Fab
first step was drain fluid, then take the pan har bar off, I did all this with my rear still under vehicle. then i took a grinder and grinded the factory weld around the cover flat. then took a air chisel and just cut around the weld which worked great it came right off. i then took rags and plastic and wrapped around the gears so no metal made its way inside while i was smoothing out the area around the diff i was going to weld to. to make sure i had no metal i sprayed a full can of brake cleaner on the gears and flushed it out good. then finally simply weld new cover on
What i used - blue torch fabrications kryptonight rear FJ 40 diff cover you could use a stock fj 40 rear cover if you didn't want a 1/4 inch steel cover this cover had to be modified a little as you can see in picture, i cut the top and bottom flange completely off
BTF Toyota FJ40/LandCruiser Rear Kryptonite Differential Cover :: Blue Torch Fab
first step was drain fluid, then take the pan har bar off, I did all this with my rear still under vehicle. then i took a grinder and grinded the factory weld around the cover flat. then took a air chisel and just cut around the weld which worked great it came right off. i then took rags and plastic and wrapped around the gears so no metal made its way inside while i was smoothing out the area around the diff i was going to weld to. to make sure i had no metal i sprayed a full can of brake cleaner on the gears and flushed it out good. then finally simply weld new cover on
