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Rear Axle Housing Question

Discussion in '1st Gen. Tacomas (1995-2004)' started by MoneyB86, May 12, 2020.

  1. May 12, 2020 at 6:17 AM
    #1
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    C76149CE-C149-4F6F-97FB-8C8B7E7ABC06.jpg My Rear Axle Housing on the third member at the bottom has a small pin hole leak. I am going to attempt to JB Weld the hole to see if I can buy some time. My Elocker housing and Axles are completely fine. I have done my research and wanted to see if I am correct.

    1.) I could cut the rear cover off and weld on a new one from Barnes 4wd. Only problem is I can’t weld and the quote to get this service done has been around $800.

    2.) I could buy a Bare housing and use my existing E Locker and Axles. I can find a used Housing for $250 locally in almost pristine condition and install it myself. Only problem is that it is from a V6 2WD E Locker and my Truck is a 4WD with E Locker. Are the housings interchangeable? From visually looking at it, it seems like it should work. I’ve attached a picture above.
     
  2. May 12, 2020 at 7:43 AM
    #2
    02hilux

    02hilux What do you mean there’s no road, I’m here

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    All 8" elocker and housing are the same, even from the t4r. But on 4r, you'll have to cut the brackets and weld on the perch.
     
    Wyoming09 likes this.
  3. May 12, 2020 at 7:46 AM
    #3
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    If I understand correctly, I can buy a 2003 4x2 Elocker housing with ABS and use it on mine which is a 4x4 Elocker with ABS.
     
  4. May 12, 2020 at 8:05 AM
    #4
    02hilux

    02hilux What do you mean there’s no road, I’m here

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    Correct. 2wd and 4wd elock axle are the same. Only difference i can think of is the backing plate ebrake cable location. But since you're using everything from yours, that wouldn't matter.
     
  5. May 12, 2020 at 8:06 AM
    #5
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    Thank you very much.
     
  6. May 12, 2020 at 8:11 AM
    #6
    gotoman1969

    gotoman1969 Well-Known Member

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    3" ToyTec coilovers, JBA UCA's, Bilstein 5100's
    Take to your local fab guy and have him throw I quick weld on the pin hole.
     
  7. May 12, 2020 at 8:40 AM
    #7
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    I tried and he wants to replace the entire rear axle. Having a hell of a time trying to find someone in the Southern Maryland area that’s not trying to up sell.
     
  8. May 12, 2020 at 8:53 AM
    #8
    gotoman1969

    gotoman1969 Well-Known Member

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    Have a good pic of location of pin hole?
     
    MoneyB86[OP] and whatstcp like this.
  9. May 12, 2020 at 9:09 AM
    #9
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    4B3EFA1C-20AD-45F1-8490-9A43E83999C2.jpg
    Here’s an older picture ( a week ago) I’ll take a different angle when I get home today.
     
  10. May 12, 2020 at 9:11 AM
    #10
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    Don’t mind the leak on the left. The Elocker actuator was cracked and I replaced it taking care of that leak along with resealing the third member.
     
  11. May 12, 2020 at 1:33 PM
    #11
    Wyoming09

    Wyoming09 Well-Known Member

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    Have you offered to just bring the bare axle housing to a welder to have fixed?

    I could see the labor to pull the differential getting expensive .

    No shop wants to chance cooking the bearing when repairing the paper thin cover.
     
  12. May 13, 2020 at 9:07 AM
    #12
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    Here’s the culprit hole. Got it down to bare metal and waiting for everything to drain out and then clean it with Acetone and JB Weld it.8DA357B6-6CF4-4C77-A59C-624BCC910F1B.jpg
     
  13. May 13, 2020 at 9:23 AM
    #13
    BT85

    BT85 Well-Known Member

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    i’m from southern PA, if you bring it to me i could weld it for a lot cheaper than $800. JB weld will have a hard time sealing on that even if you clean the gear oil and drain it.
     
    MoneyB86[OP] likes this.
  14. May 13, 2020 at 2:01 PM
    #14
    Palanterra

    Palanterra Well-Known Member

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    I'm in MD as well...Had the same problem you describe above with my 04...Started with a single pinhole, within a couple of weeks there were many more...Went the JB Weld route, as BT85 notes above never really sealed 100%...Looked at the Barnes cover...Looked into having the holes welded...Those options were not cost effective when the condition of the rest of the housing/axle were taken into consideration...Decided to replace, looked for quite some time for a used unit, finding one in acceptable (to me) condition was not easy...Those I did locate - SW US, did not make sense once shipping was factored in...I eventually bit the bullet and bought a brand new housing from Toyota...Pricey for sure, but when combined with the new frame, figured it was worth it, plus, truck now looks brand new underneath...While doing the swap, ended up basically rebuilding the entire rear end as a number of the other components were not long for this world...If you can swing it, pick up a new housing, or spend some time locating a good unit in acceptable condition...There is a lot of junk out there advertised in 'excellent condition'...Good luck
     
    ELMO67 and MoneyB86[OP] like this.
  15. May 13, 2020 at 4:01 PM
    #15
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    That seems like the best route to me as well. However I found one of my neighbor is a professional Welder. I’m going to hook up his stereo system and he’s going to tack the hole up and then weld over a Marlin Cover for me. The Marlin is welded over the existing housing and he’s going to seal the fill plug hole for me as well around the marlin cover. In case the inner housing leaks, the outer marlin cover will act as a second layer and keep the oil in the axle. This will buy me some time and allow me to save $$$$ for a new housing.
     
  16. May 20, 2020 at 4:54 AM
    #16
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    ED6C6B6B-771D-427C-B603-54C1290EBDB0.jpg Just wanted to provide an update. My neighbor came over and tack welded the hole shut. There is now a nipple on the area of the original hole. I then took a syringe filled with JB Weld and filled in the outside gap of the weld to fill in any potential holes. After 24 hour setting time, I scuffed up the original application and applied a second layer of JB weld. Going on 2 days without a leak. This will buy me some time until I can find a good deal on a new housing
     
  17. May 20, 2020 at 4:55 AM
    #17
    MoneyB86

    MoneyB86 [OP] Well-Known Member

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    FYI, I made sure to get the metal to bare shiny surface, scuffed it with some sand paper and then cleaned it with acetone prior to the JB Weld application.
     

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