rear differential 2000 4Runner

[bcde1]

Newbie - please help!

I own a 2000 4Runner Limited and the rear differential housing has rusted pit holes at the pumpkin. A bonded patch has been applied by the dealer and that only held for about 10 months.
Now I am told by the dealer (Toyota) that the only remedy is to replace the housing (parts and labor $1700). Any suggestions?

Also, I would think that the steel housing should be thick enough that this type of problem should not exist even for a vehicle located in Vermont where salt is used in the winter.

Does anybody know exactly how thick is the steel in the differential at the pumpkin area?

Thanks,
Ed

 

[004Gunner]

Try a salvage yard and the part should cost half of that, maybe less if it is not a locker. Installation is a different matter but you could still save significantly. That is a severe rust issue but if it isn't washed throughout several winters, I could see it happening up there

 

[ziggy]

rear differential housing rust

I thought I was all alone with this problem. My 2000 with 57,000 miles has the same problem. The differential housing rust was flaking off in pieces the size / thickness of a quarter. Even though there was no actual hole, the metal is so thin in places that I could see fluid come through the metal and form drops. I looked at cost on the web and decided to repair myself. I drained the fluid, wire brushed the housing, cleaned with brake cleaner and coated several times with JB weld. I thought I was all set but a drip occured. The cause - the breather plug was rusted shut (located on the top of the rear axle) and was causing the system to build pressure. I replaced the breather and coated again and it has been holding. What a poor design and poor quality of materials. I'm thinking of bringing it to a local welder and have the differential cover removed / ground and welding in a new cover. I just need to find a cover from a similar sized vehicle. Please let me know how you make out and the approxiate costs to repair. You are not alone ....