Rust and leaking differential cover.

Has anyone experienced a rusted and leaking rear differential cover which is part of the housing on a 2004 or similar Toyota Tacoma. What’s the best remedy for this problem.

 

First you can clean as best as possible drain the gear lube and try JB weld . Short term fix at best

Some just opt to replace the complete axle housing

The real fix with your axle is to remove the rusted cover and weld on a new cover.

There are some weld on after market covers or you can make your own .

Being real careful controlling the heat it is possible to do without removing the differential

Pray tell what is the rest of the frame like??

 

To weld a new differential cover does the housing have to be stripped of all of its components ?

 

If your real careful controlling the heat it can be done without removing the differential Weld in small stitches around the cover not getting anyone area to hot.

if your comfortable welding out of position .

If your planning to remove the axle housing then you may as well strip things out

cleaning is very important in any case once the old cover is removed

Doing any vehicle but my own I would remove the axle housing and strip all the parts.

best of luck!

 

has anyone here tried the farmer fix method of brazing, by chance? Does it even work here?

 

Do you have a picture of where it's leaking? I've seen 8" pipe caps welded on as armor. But you would need a good base to weld to.

 

Are you thinking to just braze the area that leaks ??

Braze the whole new cover on sure if your brazing skills are up to speed.

You would fix one spot a few weeks later another spot then another. Getting things clean enough would also be a problem .

Once the rear cover starts to rust may as well just replace the whole cover

 

Once the old cover has been removed the rest of the axle housing is a very good base to weld to once you get it clean enough.

That is the hardest part cooking the gear oil out.

Another weight saving idea that looked real good on paper.

 

I mentioned brazing because I've used it before successfully on other projects and it seems it would work good to patch up the leaky spot.. however, I've never tried it on one of these damn Japanese design rear ends.