Differential Thinking
This exclusive has you covered
INNOVATION CASE STUDY | DOWNLOAD PDF
Toyota trucks may be legendary for their toughness and reliability, but their solid axles have a weak spot that often sends owners to salvage yards and online forums in search of answers.
Underneath 4Runner, FJ Cruiser, Tacoma and Tundra vehicles, the cap that covers the differential is made of thin-gauge stamped steel, which lets rust eat away at it faster than other areas.
The first sign of failure is typically a wet spot on the outside of the cover, or a small drip on the ground under the axle. Left to corrode further, the axle loses fluid, or water gets into the housing, mixing with the gear lube.
Fixing it hasn’t always been simple.
These covers are welded in place, not bolted on like other trucks, so they’re tough to replace by themselves. In the past, you’d have to get a whole new axle from the dealership, replace the axle with a rust-free salvage part, or fabricate a replacement cover by hand.
We’ve seen these homemade diff cover patches. They aren’t easy or pretty. And if you live in a rust-prone area, odds are salvaged axles near you will also be rusted. That means you have to source an axle from outside your region, which can get pricey.
That’s why Dorman designed OE FIX replacement differential covers for Toyota trucks. They’re made of heavier stamped steel for greater rust resistance, and come pre-primed.
Installing this solution still requires cutting off the old cover and welding on the new one. On the next page, we show you how to do that.
With this exclusive fix in your arsenal, Toyota truck owners won’t be searching forums and salvage yards for solutions – they’ll be searching for the number to your shop.
Problem:
The differential covers on Toyota trucks are made of thin-gauge steel that corrodes faster than the rest of the rear axle housing. With their weld-on design, the dealer’s only solution is an entire new axle assembly.
We built a replacement differential cover that can be welded on while preserving the original axle assembly. It also features heavier-gauge steel for a longer service life, and arrives ready to install with a weld-through primer finish.
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