2000 to 2006 Toyota Rear Diff cover Replacement

I cut off and weld on a new rear diff cover on this Toyota Tundra. I hope you enjoyed the video!!! If you did give this video a thumbs up and please subscribe!!! Thanks Holden!
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[@JonnyDIY]

Great job. It's a mystery to me why they didnt use a bolt on cover 🤷‍♂️🤦‍♂️

[@MrHadzo]

Good video. Small suggestion for anyone about to do this. Remove the spare tire. You’d be surprised how much room you gain. 👍

[@jh8283]

Loved the dedication of fighting around the e-brake cable. That would have driven me crazy

[@HoldenPowell_]

I just hung something heavy on it and it helped get it out of the way a lot lol

[@jh8283]

@@HoldenPowell_ good idea 😂

[@jmb-cm7mr]

I finally bought a cover and paid a Welding shop to install it even with a lift it took them 3.5 hrs but they removed the brake cable so they would not have to work around it then they under coated it for me looks good. they charged $325

[@HoldenPowell_]

That doesn’t sound like a bad deal!!

[@RobertSmith-dj3qw]

where? I can't find anyone around me to do this job. I'm NY suburbs.

[@kennethmorgan2704]

They gave you a GREAT deal...

[@quickshot4050]

@@RobertSmith-dj3qwif you live in cny I can do this for you, about to do it on my truck, lemme know if you’re interested.

[@quickshot4050]

@@RobertSmith-dj3qwif you’re still looking for someone to do this let me know.

[@Jared_Albert]

Thank you! Gave me the courage to do this on my '02 Sequoia For anyone on the sequioa. I took out the spare tire, the lateral control rod and moved the brake lines up. Used the cheap Chicago electric HFT flux core and the .030 wire max and 8 wire speed. flushed it with brake cleaner and changed the gear oil 4x to get it clear of all particulate after driving a little. used a cable come along to pull the frame and diff together to replace the lateral control rod. took a while and 4lbs of flux core because I am a total novice welder but it doesn't leak and the Dorman cover works fine. I also ground off one of the brake mounts and rewelded a new jury-rigged on which uses a zip ties, since it didn't line up perfectly. The new cover maybe the bolt is a little high, but it's close to 4 quarts more than the 3.75 factory spec

[@brian1192]

How’s it coming out? Btw how much do you think a job like this would run me

[@Jared_Albert]

@@brian1192 It worked fine. I've put about 1k miles on it since and no problems. I did change the gear oil 4 times and then bought a spare plug to switch it out until there was no more metal shavings. So far so good. Of course the Sequoia only has 250k miles:) but in the NE the rust is the killer. As for the cost, I really don't know. I was quotes around $3500 to replace the differential with a warrantied used + new control rods, but didn't shop around. You might try a twisted wire cup on your angle grinder first to take all the scale off the existing cover, if you can spot the pin holes, drain the oil and try welding some thin steel sheet over those pinholes and see if that holds, before you go through the whole thing that Holden Powell demos. You'd have less to lose if it doesn't work. Like I wrote, I was a total beginner 'welder'. I practiced a little with the HFT chicago electric welder then I went under the truck and did it. it took 4lbs of wire because I had to keep griding where it leaked throgh the weld, but after a bunch of hours, it holds. Not bragging at all, just to say that a few times I thought I wasn't going to get it done and looked on Ebay for a used rear axle so if you can weld over the existing cover, if I had thought of that I iight have done that first and not had to deal with all the filings etc. Best of luck!

[@ruralliving4034]

I'm about to do this on my Toyota Tacoma. I tried patching it and it worked for a while but is now leaking again. Thank you for the video. Everyone I talked to said I have to remove the axle to do this job. Glad I stumbled upon your video!

[@HoldenPowell_]

Glad to hear I could help!

[@ruralliving4034]

I just did it! What a frig getting that old leaky cover off. I used a cold chisel to beat the cover off after grinding the factory weld paper thin. That left me with a nice flat surface to weld the new cover on. She looks great! flushed it out and filled with fresh fluid. You saved me a ton of money. All the shops around here wouldn't do it that way. They just said to get a new axle. Thank you! I will never buy another Toyota! Designed to fail if you ask me!

[@HoldenPowell_]

@@ruralliving4034 that’s awesome!

[@benschmolze1266]

My hat's off to you, Sir! That was an awesome job and I'm about to do the exact same thing. It's amazing how close the gears are to the edge of the cover. Guess you just have to be real careful not to cut too deep eh? Thanks for the video.

[@brian1192]

Did you end up doing it ?

[@benschmolze1266]

@@brian1192 no, i scrapped the truck. The whole rear end was leaking and the frame was shit. Diff cover would have been a waste of time.

[@kennethmorgan2704]

look like a good job, and didn't even jack the truck up which to me would have made it easier, that is my guess, but thanks for the video, I will probably be doing this junkie 2003 Tacoma the same way...

[@Tundra_Guy]

How did you make sure that no metal shavings were sent into the diff? That's the only thing stopping me from doing mine.

[@HoldenPowell_]

There we’re probably some small amounts, I cleaned it our real good afterwards and if any little amount is left it should get stuck to the magnetic plug after you put oil in I’d think.

[@brianlightner4918]

So, I'm faced with the same issue, but lack the skills sir; how much would you charge to a job like that?

[@tannervermillion3520]

What cover did you use?

[@douglasmcgowan2372]

Any concerns with grinder wheel contamination indifferencial

[@HoldenPowell_]

No

[@michelleroy2444]

Hi I have a 06 Tacoma and I can't find a cover that firts my truck can you tell me where you got your?!

[@r.q.5457]

Holden , nice work! Can you please share the welder settings? It’s a cast iron axle right? I figured on using .035 wire , Argon/CO2. You remember the amps or IPS? Thx Btw, my cover had a very slight leak in November. I waited till spring, now the oil is running out. Don’t delay, in using POR 15 on this cover.

[@HoldenPowell_]

I used .035 wire and 75 25 mix gas and I use to be a welder for a living so I just eye balled it until the weld looked like I wanted

[@r.q.5457]

K, thx. I ended up spreading a 1/8 inch or so of JB Weld across the whole diff. I then put 6 coats of Flex Seal. Its a 22yr old Tundr Ltd., off road with 220k miles. Time to move on. I will let the future owner know. Looking for a 2015 Taco Pro, off road.

[@kbomb25]

Nice work. I’m interested in having this done. How much would you charge to do this again if I brought the truck to you? I live in Maryland.

[@HoldenPowell_]

I think I’d pass on doing it again unless I had a vehicle lift to put it on. It made it way more difficult on the ground doing it it was hard and wasn’t fun 😂 it took me 3-4 hrs to do it non stop.

[@eugenehill3167]

What did you weld it with what were you welding with ? If a stick welder what type of rod would you use? Thank you

[@HoldenPowell_]

I used a Miller mig machine

[@twill9278]

My rudimentary knowledge tells me that stick welding cast iron requires nickel rod

[@robbiesands166]

Hey its impossible for me to find a mechanic who's willing to do this repair on my 04 sequoia. Any Recs? Mine looks just like yours. I'm located in the Philly area

[@Catfish4570]

Mine is leaking through the cover now so i might have to do this

[@HoldenPowell_]

It’s definitely a little bit of a process, it would of been way easier if it was on a lift but don’t have one of those lol. I probably should of stuffed some towels in the Diff before grinding to but it was a learning experience

[@Catfish4570]

@@HoldenPowell_ I think I'm going to try and JB steel weld it first

[@jmb-cm7mr]

@@Catfish4570 I did that it held for about 8 months

[@RobertSmith-dj3qw]

looks like a Dorman cover? I have a 2005 tundra SR5 extended cab 4WD 4.7L, will that cover fit? what's the model #? 926-958 Dorman?

[@rayray31able]

I have a 2006 SR5 that needs the same thing did you find out if the dorman 926-958 fits?

[@RobertSmith-dj3qw]

@@rayray31able bought on Amazon. Dorman 926-958 fit perfectly. Had a local welder cut off the old and weld on the new for $375 labor. I supplied the cover and oil. Oil I used was Castrol Axle limited slip SAE 80W-90 API GL-5. My rear had LSD posted right on the diff cover.

[@RobertSmith-dj3qw]

@@rayray31able sorry it took me 12 days to respond, I just saw your question today.

[@rayray31able]

No I've got a new problem my airbag light came on and dealership says it's a sensor in my bench seat good luck trying to find a bench seat for a 2006 tundra 60/40 with airbag sensors in it I'm looking at $2,000 just to get it replaced

[@RobertSmith-dj3qw]

@@rayray31able you better do some internet fishing before spending that cash. I'm sure there's some hack to circumvent that sensor.

[@joesezzz4324]

2003 Tacoma same thing

[@Red22GS3]

Great Job! I'm a little late to the party.😂 Do you recall where you purchased the cover? I have an 2004 Tundra that started leaking.

[@HoldenPowell_]

The guy I did it for brought it with him

[@ivotedfortheamerican]

NAPA sells them

[@brian1192]

How much would a job like this run me ?

[@douglaspitcher2478]

Would Toyota do this fix??? If not where do I go?

[@HoldenPowell_]

Probably but it probably wouldn’t be cheap but might be the same as other places idk

[@jmb-cm7mr]

Where did you get the cover from ?

[@HoldenPowell_]

The guys I put it on for already had it so I’m not sure, sorry

[@stevesteinecke2791]

Dorman.Twice as thick and primered. 52 bucks

[@brianpacheco1927]

Stupid design choice by Toyota I ruined my factory open diff at least now when I do this I can put in an Eaton TrueTrac.

[@beckyromineciy5410]

Yeah....let’s get metal shavings all up in the diff???wtf if you can grind and weld it’s all through bolts. Take it apart... don’t show ppl a wrong way....

[@HoldenPowell_]

There’s one bolt on the hole thing and its the fill hole. If you know a better way to remove a weld on diff cover then let me know. Obvious if you watched the whole video you will see the new diff and see there is not a single hole in it besides the fill plug.

[@richardcomeau8231]

Design flaw by Toyota it’s all that can be done, But I was wondering did you clean it out after grinding? Would spraying it with brake cleaner clean it out

[@mktrollop1093]

@@HoldenPowell_ I think he means you should have stripped the axle down to the casing first. Don't think I'd have bothered myself but probably is the right way to do it in fairness

[@yojoebananas]

@@mktrollop1093 Brake clean, fill the diff with fluid, drive 1 miles, and flush it out, put new stuff in, repeat, then put fresh stuff in and should be all clean

[@JonnyDIY]

Just save the old diff fluid when you drain. After removing cover, cover open diff with towel to prevent shavings. Brake clean before putting new cover on. Refill with old fluid and drive a bit. Drain and fill with new 👍