Leaking rear diff

Hi All,

I have been looking through the forum and found some info on the first Gen tundra but could not locate much on the second Gen. My rear diff cover is leaking on my 2010 2wd 4.6l tundra. When searching for new weld on covers I could only find ones made for the first Gen up to 2006. What are the options to get this fixed? Are there weld on diff covers available for the second Gen tundra ? I see can buy the whole axle housing for $1500 but that is an expensive route!

 

Is it rusted through? Haven't seen any like that on the 2nd gen here. Got any pics?

 

Crazy rusty

 

I can't get the filler bolt out either to check the level. Tried this morning. It's become one with the axle housing. First used a 24mm socket and breaker bar. That rounded the metal instantly. Even going to a chisel and hammer I could not release it. Used a torch to heat it, pb blaster. I have neve encountered something so stubborn and the metal is super soft. Ugh

 

Time to head to the junk yard and scrounge up another axle

 

Could take some measurements and see if the first gen cover would work or not.

$56 Dorman 926-958 Rear Differential Cover Compatible with Select Toyota Models (OE FIX)

LINK

 

I made one for my 1st gen Tundra when it rusted through. The rear cover is very thin metal. I just used a 4 1/2" grinder with a cut off wheel to remove the thin rusted metal. Then I just used some 1/8" flat bar (maybe 2" wide) and bent it by hand to fit around the rear diff. Then I used some diamond plate steel for the cover. I welded a 1" steel (not cat iron) female coupler that I cut in half so I could fill the diff. A 1" plug makes for lots of room to fill the axle up and see how close it is to full. It wasn't perfect but it was pretty easy to do. But I have a 2 post lift in my garage so I wasn't on my back. Much easier than trying to find an axle that wasn't rusted.