Rear Diff Sprang A Leak!

[WoofsPlow]

My 1995 Toyota pickup has a leak in the rear diff. It's rusted pretty bad and must have gone through - does'nt look like I hit anything. What is the best way to repair? The cover is fully welded at factory so I just can't get a replacement cover. I have not had time to fully look at the extent of the damage. Can the hole be welded? I am concerned there is not enough material left. One I start gringing I may end up with a huge hole. What can I do for temp. repair that could get me through the winter. The diff is approx 8" from center to bottom. Bot of fill plug is about 6" from bottom of diff and leak seems to be about 2" below that leaving me about 4" of fluid. Fill with synthetic and hope for the best? Does the diff have any pressure or is it just a housing for the fluid? Any help is appreciated. Thanks, Jim:(

[wyldman]

There isn't really any pressure in the diff,as it's vented to the atmosphere.

I have seen many types of repairs done to leaking axle housings.The one I prefer is liquid steel,or any type of steel reinforced gas tank repair kits.Just clean it up some with a wire wheel,hit it with some brake cleaner to remove the oil residue,and the apply the patch.If the kit comes with a fiberglass or steel mesh\screen,do not use it,you only need the repair putty.

When you put it on,don't mess with it much.Just one or two good swipes,and thats it.If you mess with it trying to make it look pretty,it will most likely leak.

I have also see guys clean it off,and smear silicone all over it.While it does work,it's usually not quite as successful as the other repair above.

[WoofsPlow]

Thanks Wyldman, I was thinking along those lines as well. The only problem is every time I use one of those products it never seems to work. Is there a product name you have had success with? I was also thinking of useing silicone as an alternate - what about duct tape over the patch (I know). There is snow falling now (4" before change to ice/rain) so time is a factor. Thanks again, Jim

[wyldman]

I wouldn't worry too much about it for now,just make sure the diff is full.Due to the high viscosity of the diff fluid,it should leak very much.It will be fine until you have time to repair it.

[WoofsPlow]

Thanks - what kind of diff fluid would you recommend?

[wyldman]

For now,just top it off with any 80W90.When you have successfuly repaired it,then maybe look at a synthetic gear oil,so you don't have to mess with it for a while.

[WoofsPlow]

Thanks for the help! I will post some pics for your enjoyment.