1. Welcome to Tacoma World!

    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 Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Rotten Rear Diff Cover Repair Suggestions??

Discussion in '1st Gen. Tacomas (1995-2004)' started by Buckyk0j1r0, Jun 5, 2019.

  1. Jun 8, 2019 at 2:05 PM
    #21
    12TRDTacoma

    12TRDTacoma Powered by Ford, GM, VW, and Mercedes

    Joined:
    Aug 20, 2012
    Member:
    #85133
    Messages:
    16,671
    Gender:
    Male
    First Name:
    Rob
    Concordia
    Vehicle:
    12 TRD Sport DCLB 4x4 Supercharged
    Boosted
    Dont mind me, I'm just here to observe and admire.
     
  2. Jun 8, 2019 at 2:53 PM
    #22
    Hoots Magoon

    Hoots Magoon Well-Known Member

    Joined:
    Feb 15, 2019
    Member:
    #283168
    Messages:
    88
    Gender:
    Male
    Rhode Island
    Vehicle:
    2004 Tacoma TRD
    Also, when welding on the Barnes cover, don't forget to have the fill plug at the top. Don't ask me how I know this.
     
    Wyoming09, jammer and Wulf like this.
  3. Jun 9, 2019 at 10:07 AM
    #23
    jbrandt

    jbrandt Made you look

    Joined:
    Feb 12, 2011
    Member:
    #51038
    Messages:
    17,612
    Gender:
    Male
    First Name:
    Justin
    El Dorado, CA (NOT El Dorado Hills)
    Vehicle:
    '04 TRD Tacoma 4x4 DC
    Kings, J59's Total Chaos UCAs Custom skids Sticker mod
    They are also better protected (better paint coatings) and in less direct contact with the road salts.

    Note I didn’t say body panels don’t rust. It is just typically not as big of a problem as the frames.

    Toyota doesn’t have an extended warranty replacement on body panel, either...
     
    GQ7227[QUOTED] likes this.
  4. Jun 9, 2019 at 3:13 PM
    #24
    tony2018

    tony2018 Well-Known Member

    Joined:
    Feb 24, 2014
    Member:
    #123866
    Messages:
    5,285
    Gender:
    Male
    The stock fill plug is to the side though, why would the barnes one need to have the fill plug in the top placement.
     
  5. Jun 9, 2019 at 3:27 PM
    #25
    Hoots Magoon

    Hoots Magoon Well-Known Member

    Joined:
    Feb 15, 2019
    Member:
    #283168
    Messages:
    88
    Gender:
    Male
    Rhode Island
    Vehicle:
    2004 Tacoma TRD
    The one I got was like this, not like the one pictured previously in this thread.

    Screen Shot 2019-06-09 at 6.26.15 PM.jpg
     
  6. Jun 10, 2019 at 12:03 AM
    #26
    ThunderOne

    ThunderOne Well-Known Member

    Joined:
    May 20, 2009
    Member:
    #17473
    Messages:
    10,043
    First Name:
    Mitchell
    Nashville
    Vehicle:
    1ST GEN OR GTFO
    Toyota NERD
    Good lord. What size Allen key do you need to remove that fill plug?
     
  7. Jun 10, 2019 at 12:22 AM
    #27
    UtahTacoma02

    UtahTacoma02 Well-Known Member

    Joined:
    Dec 5, 2014
    Member:
    #143730
    Messages:
    691
    Gender:
    Male
    First Name:
    Dave
    SLC
    Vehicle:
    02 Tacoma Double cab TRD Limited
    ARB front bumper, Old Man Emu suspension, on board air compressor, on board hot water converter, cb radio, safari snorkel, warn 8K lb. winch, AP rock slidders/rear bumper, gray wire mod
    Looks similar to the 10mm plug on the front diff. That would be my guess.
     
  8. Jun 10, 2019 at 12:27 AM
    #28
    robssol

    robssol If it ain't broke, leave it the eff alone!

    Joined:
    Jun 4, 2013
    Member:
    #105622
    Messages:
    7,681
    Gender:
    Male
    First Name:
    Rob
    S. Wisconsin
    Vehicle:
    06 Tacoma, TRD Sport, SR5, 4X4, AC
    Totaled but still alive! Frame 2.0, Fog lights anytime, Seatbelt reminder delete, Secondary air filter delete, LED bed lights, Running boards, 2017 Rims, Ultra gauge, Cup holder/consol/glove compartment lights, Interior LED conversion, Blue Sea aux. fuse panel, fuse panel mounting plate by Yotamac, ProEFX heated towing mirrors, LED engine bay lights, Redline Quicklift Elite hood struts, Wet Okole Heated Seat Covers,m, Rear bumper 2.0, Decal free visors, Washable cabin air filter, Overhead consol auto dimming override switch, BulletProof Fabricating Skid plate, 2lo module.
    Welcome to TW!:hattip:

    I always try to replace with new or like new parts if possible.
    Good Luck!:mudding:
     
    Taco critter likes this.
  9. Jun 10, 2019 at 1:06 AM
    #29
    ThunderOne

    ThunderOne Well-Known Member

    Joined:
    May 20, 2009
    Member:
    #17473
    Messages:
    10,043
    First Name:
    Mitchell
    Nashville
    Vehicle:
    1ST GEN OR GTFO
    Toyota NERD
    One would hope! I hate those hex fill plugs regardless.
     
  10. Jun 10, 2019 at 1:13 AM
    #30
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    14,277
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck 5 speed 4x4 3.4
    Super Springs
    might be 1/2" just put the ratchet in done.

    As long as the plug is at the same height you could put it anyplace
     
  11. Jun 10, 2019 at 5:25 AM
    #31
    ToyRyd04

    ToyRyd04 Taco Transformer

    Joined:
    Aug 5, 2011
    Member:
    #61217
    Messages:
    1,884
    Gender:
    Male
    First Name:
    Greg
    Perryville, MD
    Vehicle:
    '04 PreRunner
    SAS'd PreRunner Diamond Axles Crawlbox
    14mm hex

    Attach23776_20190610_082428.jpg
     
  12. Jun 10, 2019 at 8:01 AM
    #32
    ThunderOne

    ThunderOne Well-Known Member

    Joined:
    May 20, 2009
    Member:
    #17473
    Messages:
    10,043
    First Name:
    Mitchell
    Nashville
    Vehicle:
    1ST GEN OR GTFO
    Toyota NERD
    yep, tis a big honker
     
  13. Mar 11, 2021 at 3:09 PM
    #33
    jimmyangst

    jimmyangst Member

    Joined:
    Feb 23, 2021
    Member:
    #357175
    Messages:
    19
    Gender:
    Male
    First Name:
    Jimbo
    Vehicle:
    2002 Tacoma TRD
    Hey all! Resurrecting this thread from the dead. I have the dreaded rear diff cover leak. Ohio truck. Those of you who have successfully cut off the old and welded on the new, anyone have specifics on their weld process? Flux core wire? MIG? Stick? Asking b/c the good replacement covers (Barnes for example, which I have sitting next to me right now) are good heavy steel. I've searched the forum and come up dry. Actually gave up on the forum search and just used the googles, which led me right back here. Weird. I'm thinking stick would be better than MIG, based on my former experience. But I dunno, I've been out of the trade for many years & looking at this project as an excuse to get back into welding on the side. I'm that most dangerous of mechanics: someone who used to know something. Your advice is welcome, your abuse is probably well-deserved.

    Thanks,
    Jim
     
  14. Mar 11, 2021 at 5:11 PM
    #34
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    14,277
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck 5 speed 4x4 3.4
    Super Springs
    What ever works for you .Your the most comfortable with.

    Just keep the heat down unless your pulling the differential to keep from cooking the bearings no matter what process you decide on.

    Lots of stitch welds bouncing all over the place
     

Products Discussed in

To Top