2015 2nd Gen Rear Diff Leaking at 35k miles

Happened to stumble across my rear differential leaking gear oil right at the gasket that seals the clamshell a few days ago. This was a very steady leak with drips every second. I checked the bolts around the gasket and they all seemed torqued properly with the factory match marks still present. Breather didnt seem clogged and everything was free of mud/ dirt since its a pavement princess.

For reference my Tacoma is my daily and never had been offroaded or abused. Its a 2015 with 35k miles on it currently. Gear oil was replaced with fresh Amsoil about 7k miles ago. There are no signs of damage to the pumpkin-- no scrapes or dents.

I firmly believe that this was a factory error in installation that caused this premature gasket failure. There is absolutely no reason for a diff gasket to fail at this mileage. Decided to take it to the dealer to see if they would honor some type of goodwill service. Understandably, since im out of warranty, the dealer is refusing to cover anything. In speaking with a daft Toyota corporate rep and explaining the issue 3 times, I was told that its less than a 10% chance that they will cover the repair and that I would simply receive a service credit for my next visit IF they decide to cover it. The lady was pretty rude.

I am being quoted $680 (discounted from $800+ since I took it to the dealer I purchased from). I asked the service rep to tell the techs to use FIPG instead of the shitty gasket they are using and was told they can't do that as Toyota only recommends this monkey shit gasket. Am too busy to just reseal it myself and know I'm getting shafted on the labor. Also they only warranty this job for 12 months :/

Anyone have the same issue with premature diff gasket failure? Anyone have a recommendation on who to speak to in order to get this covered? I've attached some pictures below that the service techs took. I shouldve taken them myself but forgot and am left with these shitty pictures.

 

You won’t like this answer. So you think that a paper gasket that took 6 years to start leaking is a improper install from the factory. Gaskets leak my friend. And for a daily you don’t drive it very much, that truck sits more than it’s driven. Yep it sucks that it’s leaking I agree. Covered under warranty, absolutely not. Hey you could alway pull the tires, rear axles, driveshaft and third member, bleed the brakes when all put back together but you said you don’t have time to do all that. So I guess your paying to get it done. Yes they can could put a very light coat of FIPG with the paper gasket, when I was a Toyota mechanic that’s exactly how I put them on. Good luck.

 

I understand your point man. But bear with me, point me in the direction of a car that pisses gear oil from a factory OEM diff gasket in 6yrs. I understand gaskets fail, but rarely at the 6yr mark especially on a Toyota. Maybe I am wrong its a factory error, but its absolute horseshit that its happening as soon as it is. And yes Im stuck paying as it caught me at the worst time. I have the know-how but no time right now.

As for the low mileage, I purchased this new in my early years of college and had a second car to commute. This was pretty much kept as new as I could keep it in my early years of owning it. I'm now starting to rack miles up but I dont commute far for work and I still have a second vehicle.

 

Have you stuck a torque wrench on the nuts to make sure everything is tight on the 3rd member? Thats free and quick. 18ftlbs i believe (dont quote me on that)

 

Those low mileage 2015 4wd are selling for a good amount down my way. I looked a two yesterday 37k ea. Crazy!!

 

Yeah they were checked and they didnt back out. Factory match marks are also still lined up too.

 

They sure are man! This market really be tempting me to sell. But I like my 2nd gen too much to do that!

 

I agree that it shouldn't be leaking that soon but I also wouldn't expect it to be covered by anybody. Sometimes shit happens. Your options are to pay someone to do it or do it yourself for $50 and 4 hours of your time. The answer to that depends on how much you value your time.

 

Most definitely! Absolutely right that sometimes you're up shit creek without a paddle. Maybe I'm being unreasonable to want Toyota to cover it...

 

Yeah. I was at the dealer the other day and they offered me 30k for mine and it’s a Prerunner. My truck is way to clean for me to sell and I like the 4.0 way too much.

 

Not to mention the markup that you'd have to pay to replace it with something else. 3rd gen Tacomas are even more expensive than the 2nd gens were and now with the markups, you're looking at a $45k truck. Insane.

 

I didn't ask if someone else checked... Have YOU checked.

Just cus factory match marks line up doesn't mean that studs havent stretched or gasket hasn't compressed.

Over the 120k on my 2013 I have def had to retorque mine down.

 

Sucks that this happened, but it is out of warranty. Unless it is a common problem (we all know about the 3rd gen issues), or you have bought multiple vehicles from that dealer, it is not likely they will use their goodwill dollars on fixing it for you for free.

That truck has had some work done on the rear end as well -- those are not stock leaf springs. Somebody jacking it up improperly to do the work could have put some strain on that seal (or it may have been slightly damaged during original assembly), and the switch to synthetic may have helped things along just enough for it to begin leaking. I'd just get it cleaned up and fixed and put it behind me. Not a common thing on a Toyota, but it happens.

 

Hmm, fair point about the possibility of jacking the vehicle from the diff straining the seal. Although I personally have not had such issues or heard of it happening, with it being a paper gasket I can see that being compromised very easily. And yeah I guess you're right about the whole goodwill repair not being likely. I'm for sure frustrated and was super curious if this was a common leak on the 2nd gens like the 3rd gen guys have. Guess I should re-assess my expectations

 

Are you the original owner? As clean as the truck might be if someone owned it before you something could have happened to the truck.

 

Yes Im the original owner. I purchased it new off the lot

 

Been there, man. I had a 2009 that had the issue with the DRL's melting the housings. I didn't notice it until right at 37k miles, just out of warranty, but it had obviously not just happened. The dealer at least took pictures and sent them to corporate, but they came back with a nope. So, I got real mad, used some Google-Fu and found the email for the president of Toyota USA, listed out all the Toyotas I have owned and explained that this is not what I am used to or expect from Toyota and would be considering other brands in the future. Corporate called me and sent me in to get it fixed. Later they released a TSB and extended the coverage on those housings. But in this case, it was a common problem, just not common enough at the time I went in.

 

Give the bolts a little ugga dugga might compress the gasket enough to stop the leak

 

It wouldn't hurt to check the relief valve on top of the housing to make sure it isn't seized and the diff is building pressure. I give mine a spin every once and a while to make sure as dirt and mud can seize it shut.