rust

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SAYWHAT

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Cover on rear differential is almost rusted to the point of perforation. What kind of cure is available for this?
 
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I had the same issue. While changing the transfer case oil, I noticed oil slowly dripping out of rear diff. It was bad, big thick flakes of the diff were falling off. The leak itself was probably around the seams and/or pinholes.

I think there are aftermarket parts (Toyota Pick Up Heavy Duty Differential Cover) but it's easier to just find a used rear diff housing. Worst case, you may have to buy the whole rear diff.

Price it out to see if it's worth it for you. If not, there's always JB weld.
 
jaephu said:
I had the same issue. While changing the transfer case oil, I noticed oil slowly dripping out of rear diff. It was bad, big thick flakes of the diff were falling off. The leak itself was probably around the seams and/or pinholes.

I think there are aftermarket parts (Toyota Pick Up Heavy Duty Differential Cover) but it's easier to just find a used rear diff housing. Worst case, you may have to buy the whole rear diff.

Price it out to see if it's worth it for you. If not, there's always JB weld.
Click to expand...


I just got done putting one of those on. Great product, but you better have some good tools, or know someone who does, to do it. The cover took 30 min to replace? Cutoff wheel makes short work of things. Run it down flat and put the new part on. We used a MIG on it, had both sides welded up in about 10 minutes. I wouldn't want to try it with a flux core rig.

Anyway, the hardest part was r&r of the housing on my back in the garage. Adds about 2 Qts of capacity and won't ever have to worry about it again, which you can't say about JB Weld. What happens when that epoxy fails, or the cover rusts through in another spot and you don't catch it in time? And, the best part, if you do the labor your self you're out 80 bucks and some oil, instead of the cost of a housing that might have the same problem down the road.

Do it once.
 
I just tore into mine last week. I shaved the bottom of the housing and replaced the bottom 1" of the diff cover where the leak was. I had seeping oil for about a year now.

FWIW, that cover is slightly less than 1/8" thick, it had big flakes of rust but it wasn't weak by any means. I'm in MN conditions and I can't imagine anyone having much worse rust. It has been a huge project, by far the hardest part has been cleaning the housing back out from the cutting/grinding/welding debris. If I was to do it again, I would just remove the third sand blast the cover, and weld up the hole. I would make sure you stop the rust and not just cover it though.

Maybe there are people who had covers that look like swiss cheese but I didn't see any when researching it, just lots of talk of replacing the entire axle or JB weld.
 
tacojeff said:
I just tore into mine last week. I shaved the bottom of the housing and replaced the bottom 1" of the diff cover where the leak was. I had seeping oil for about a year now.

FWIW, that cover is slightly less than 1/8" thick, it had big flakes of rust but it wasn't weak by any means. I'm in MN conditions and I can't imagine anyone having much worse rust. It has been a huge project, by far the hardest part has been cleaning the housing back out from the cutting/grinding/welding debris. If I was to do it again, I would just remove the third sand blast the cover, and weld up the hole. I would make sure you stop the rust and not just cover it though.

Maybe there are people who had covers that look like swiss cheese but I didn't see any when researching it, just lots of talk of replacing the entire axle or JB weld.
Click to expand...

Mine originally came from Chicago. I had 1 complete failure point and 3 other spots that I could've poked through had I used just a bit more pressure. So they were close to being a problem. All 4 spots were around the brake line bracket.
 
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