Differential Overheating in '06 SR5 4WD DC LB

Hey folks:
Halfway through a 600km highway drive on snow / slush / rainy roads I put my Taco in 4H. It went into 4H with no problem and the light on the dash was indicating a correct 4H condition. Roughly 150 km later we stopped for a toll and when we rolled down the window we smelled burning oil. Payed the toll and parked. From the inside of the cab there was no indication of a problem, no sensors or smell. Got under the truck with a light and the differential fluid was dripping off of the bottom of the diff. When the fluid was hitting the wet pavement it was actually hissing. It was extremely hot and it had sprayed all over the engine, I was quite surprised that it didn't catch fire. I called CAA and had it towed to the dealer here in Halifax. I am trying to figure out what would cause the overheat situation in the diff.
Front and rear tires sizes are the same and the truck has been religiously maintained at / by the dealer. (truck has only 52, 000km or 30, 000 miles on it)
Anyone have a similar experience? Have had the truck about three weeks, not what I was expecting from a Toyota.
Thanks; Stu

 

sounds like the pinion seal took a crap.

 

No limited slip differential in the back. Man oh man I thought she was going to burn, right there at the toll plaza.
It should still be under warranty, have to talk to the dealer tomorrow. I was in last week and drivetrain is covered to 60,000km. Are the Toyota service guys pretty easy to deal with?
Thanks for the comments; much appreciated.
Stu

 

i heard some r very hard to deal with.and some r great to deal with.the dealer i deal (hardly every)is super.u should b fine on the warr. claim though.good luck.

 

Quick update. Had the truck towed (boo) to O' Regan's Toyota in Dartmouth NS Canada on Sunday morning. I went up and put a note detailing the issue in the key drop off at the dealership. I was on course today, so was unable to phone the service personnel until 10:30 am. Well they had already taken the truck in and had it apart and put an axle seal in and topped up the fluids and were test driving it. This is all before I had even talked to anyone! Come to find out when the axle seal failed and the fluid sprayed out the pinion seal must have failed too. They are ordering a full set of seals and are going to break the diff and put new bearings in as it was sooooooo hot. Great service, they gave it back for me to drive until the parts come in. 2WD only, though (another boo). Oh well can;t beat that service I didn't think. Absolutely no questions about warranty, no problems at all. If you ever break down in Nova Scotia head for O' Regans and ask for David Stevens.
Very pleased with the service.

 

Well the front diff saga continues. We are waiting for Toyota Canada to make their minds up whether to rebuild the diff or put a new one in. Will know more on Tuesday. I would like a new one for reliability issues.

 

The stealership called and they are putting a whole new front differential in the Taco on the 28th. I had a message on the phone saying I missed a 7:40am appointment yesterday morning. Funny they never called me to let me know I had an appointment? Oh well at least I'll have my Taco for the next trip up home.

 

Sounds like you've got a good dealership there. Just hope nothing changes & they stay like that.

 

Glad things worked out for you Stu,sorry for the inconvienience.I've had nothing but solid service from Saint John Toyota over here as well.

 

Just picked the truck up. Everything covered under warranty. They figure eveything stemmed from the driver's side axle seal failure. The pinion seal was also failed. These two seal failures put together = toasted front differential. I didn't see all the parts, but the front differential PN 41110-35A10 was retailed at $2047.XX + labour. Note this is a Canadian dollar price. No questions from the dealership, very accomodating, nothing but praise for O'Regans Toyota in Dartmouth, Nova Scotia.
I also hava an idler pulley that is starting to whine. How long do I have before I have to change this out?

 

wow. glad it all worked out. i wonder if you would have been ok, letting it all cool down, switching to 2wd, and driving to safety?

 

More then likely not. The way the front end works with automatic disconnects, your axles will still be turning, thus causing friction in the front end. The amount of friction present would be exponential with a lack of oil in the diff.

 

good point. my last 4x4 had locking hubs...thanks for the clarification.

 

Other than the inconvenience of getting out to lock the hubs, locking hubs out perform automatic hubs in every aspect and then some. If you break an internal on the trail with automatics, your screwed. With manual hubs, you just get out and unlock the hubs, then hobble it home/off the tail in 2wd.