Front Differential Cover Replacement

[TEQAdventure]

I did a writeup because there was nothing really on YouTube or Mud or replacing the entire front diff cover. After 3 failures of the diff mount bushing in 2 years, I looked deeper and found the cover was toast and needed replacement. New cover comes with the OEM mount pre-installed and the aluminum around it is not fatigued from pressing bushings in and out. This also fixed the dreaded front end clunk I was having when going from R to D and also from coast to accelerate. Full writeup is covered on my blog site: 100 Series Land Cruiser Front Differential Cover Replacement - https://www.teqadventure.com/post/100-series-land-cruiser-front-differential-cover-replacement

Steps in the process are listed below. I took several photos during the process but it is not very hard. Access is the biggest issue and I recommend removing the long bolt for the cover mounted bushing and removing the driver side (lower) support arm that connects the axle housing to the frame. This will drop the differential lower, which makes access to the top bolts and vent hose much easier.

1. Remove differential fill plug, then drain plug using a torx/allen socket (whichever you can get to fit, T45 worked for me).
2. Remove the 19mm bolt that mounts the differential bushing and remove the driver side support arm. This lowers the differential for easier access
   
   
   
   
   
   Get the diff as low in the frame as possible for better access.
   
   
3. Remove the breather vent on the top right over the diff cover.
4. Remove the bracket (12mm) at the very top of the diff cover.
5. Remove the 14mm cover bolts (there is one on the backside of the cover also).
6. Pry the cover forward and let it drain. The cover will not clear the cross-member, so you can just let it hang.
7. You will need to use a ratchet strap to gain enough clearance to remove the diff cover. See photo for how I did this.
   
   
   
   
   
   Ratchet strap the axle to the crossmember just behind it. This allows you to remove the diff cover.
   
   
8. Even now, the diff cover will not just fall out. You will need to manipulate it and work it around the crossmember.
9. Once removed, you can clean the mating service, install RTV sealant and re-install.
   
   
   
   
   
   Diff cover after removal.
   
   
10. The re-install process is just the opposite of what you just did.
11. Make sure the drain plug is reinstalled and add 2 quarts of gear oil. Access is tight, I found decent luck with the 1 quart bags.
    
    An important note is that if this was done previously the washer for the long 19mm bolt that holds the mount in place may be gone. If it is, you will still have a clunk, as there is a gap that cannot be filled by just the stock bold. The OEM part number for this washer is listed below, both of my 100 Series were missing this part.
    
    
    
    
    
    Toyota Washer/Plate Part Number: 41654-04020