Topic: Front diff drain plug???

[yota pu/runner]

So I went wheeling two weeks ago and just happened to rip the drain plug out of my front axle .   I have an 80 pu and what I'm looking for is if someone knows the size or knows where I can get a tap and die to re-thread it or if someone knows another good way to repair it.  I would like to keep it on the less expensive side preferrably.

[ninja turtle]

http://www.marlincrawler.com/htm/diff/pickup_diff.htm    or you could weld it up and never have to deal with it again.

[yota pu/runner [OP]]

Sweet that is exactly what i'm looking for.  But if you weld it up how exactly are you going to be able to drain your fluid without pulling the whole thing apart.

[ninja turtle]

you arnt.

[DTB]

Sweet that is exactly what i'm looking for.  But if you weld it up how exactly are you going to be able to drain your fluid without pulling the whole thing apart.

I thought that was a great idea too until i ripped it out (the low profile plug) on the trail too......  

best bet is to shave the hole and weld it up (or just weld it up)....to drain the fluid just remove one of the two bottom studs on the diff

[yota pu/runner [OP]]

That is good to know before I go and buy myself some new drain plugs and end up spending money when I don't have to spend any money at all.  Thank you for the info.  It will be put to use.

[DAWGTOY]

i too have knocked out drain plugs, both front and rear.
what i've been doing lately is after the plug is installed
i put a small spot weld to keep it from turning.
then when i change my oil (frenquently) i grind off the
spot weld change and repete.


 dawg

[Rocksurfer]

Weld it closed, remove the studs on the bottom 3 of the 3rd and put bolts in place of the studs. I would weld the bolt in place like DAWGTOY mentions that way if you have to open it up that way you can. Plus the magnet is still there to catch the metal slivers.

[yota pu/runner [OP]]

Thanks for the info my plan now is to weld it in place.  Rocksurfer you said replace the studs with bolts.  Do they need to be tapped or are they already threded?

[jimbo74]

Thanks for the info my plan now is to weld it in place.  Rocksurfer you said replace the studs with bolts.  Do they need to be tapped or are they already threded?

already threaded

[yota pu/runner [OP]]

perfect that will make it easier.

[Hyena]

they have to be metric bolts though since they are a metric thread.

[DTB]

Pull the bottom 2 bolts out to drain the diff

[yota pu/runner [OP]]

The pics help a ton, I'm hoping to get it done this weekend but we'll see.  More important I need to get my new power steering box bolted up first.

[Volcom]

I cut the entire drain plug out of the F&R axles when I was building my crawler.  I ended up welding 3/16" plate in place inside and out and grinding the outside smooth.  Works out very well on the rocks.

[OOPS]

I cut the entire drain plug out of the F&R axles when I was building my crawler.  I ended up welding 3/16" plate in place inside and out and grinding the outside smooth.  Works out very well on the rocks.

I ground down the outside. Chamfered the hole on the outside. Screwed the plug in from the inside and tacked it in a couple of places. Grounded it down where it was standing proud on the outside. Welded it up and ground the welded down. I JB welded a small magnet on the inside of the housing at the bottom away from the ring gear.

Since I installed 5/16 (could be 3/8 I do no remember which I used) bolts from the inside out to hold the third in place I just undo the third and and push up to let it drain. I also run copper washers on the bottom two to help stop it from leaking. I was having a problem with the lube following the threads on the bottom two bolts and having a slight drip. The copper washers and ny-lock nuts stopped it.

The reason I did the bolts from the inside was some guys have been pulling the diff. studs out of the housings on really tough sections.

[Volcom]

Good idea about the JB'ing the magnet on the inside of the housing.  I'll have to do the same next time I have the third out.

[DTB]

I used bolts going from the outside in....seems to me that if there is anything sticking out (anything at all, like a stud, nut or bolt) it is gonna get bent or broke and will LEAK.....

only problem i can see with this is that the allen bolt could get rounded off...but so could anything else

[OOPS]

I used bolts going from the outside in....seems to me that if there is anything sticking out (anything at all, like a stud, nut or bolt) it is gonna get bent or broke and will LEAK.....

only problem i can see with this is that the allen bolt could get rounded off...but so could anything else

After seeing 3-4 rear ends pulled out of the housings I decided to drill and tap the holes bigger. Then I ran the grade 8 bolts from the inside out.

[Redeyejedi]

volcom, do you have any pics of your axle with the plates?

[Volcom]

volcom, do you have any pics of your axle with the plates?

[yota pu/runner [OP]]

wow that sure does look nice, I'm pretty sure I'm just gonna weld the plug on and call it .

[DTB]

After seeing 3-4 rear ends pulled out of the housings I decided to drill and tap the holes bigger. Then I ran the grade 8 bolts from the inside out.

smart thinking...looks like i might be doing this in the future......i got a giant puddle of gear oil on my gayrage floor right now

[havik]

maybe i am slow but how do you drain the diff if the bolts are from the inside out?
i like the idea of going with bigger grade 8 hardware.

[jimbo74]

maybe i am slow but how do you drain the diff if the bolts are from the inside out?
i like the idea of going with bigger grade 8 hardware.

when you crack the bolts loose, all the fluid will pour out the bottom, the third isnt stuck anymore

[havik]

got it now
thanks Jimbo