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Diff filler plug.

 
 
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horsethief
Articulating


Joined: 22 Dec 2009
Odometer: 502
Location: Ashton under Lyne



PostPosted: Wed Sep 05, 2012 3:40 pm    Post subject: Diff filler plug. Reply with quote

Been doing some seal replacments on my front diff,as the o/s was weaping and the prop was leaking.Now I've ran my vit for 2 year now with the filler plug threads almost stripped,just tightened it till just before it clicked loose.It's not leaked and I've had it wirelocked so it'll not come loose.But what I need to know is there a repair for the steel plug to alloy casing or filler plugs that'll cut the new thread?
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Big Hammer
Winch Assistant


Joined: 09 Sep 2007
Odometer: 62
Location: Dormerset



PostPosted: Wed Sep 05, 2012 8:36 pm    Post subject: Reply with quote

Can you use helicoils?
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vitara_mad
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Joined: 13 Feb 2007
Odometer: 888
Location: dronfield



PostPosted: Wed Sep 05, 2012 10:18 pm    Post subject: Reply with quote

just replace the case its the easyest option if its the threads in the case that are gone

pm me if you want a case

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horsethief
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Joined: 22 Dec 2009
Odometer: 502
Location: Ashton under Lyne



PostPosted: Thu Sep 06, 2012 1:58 pm    Post subject: Reply with quote

I can use helicoils if I can get them,but it'll need a new plug and the cost.I've just done the seals in this one and I've got a spare diff thanks,the prob with my spare is the filler plug is seized in.Might take it apart and drill it out.Just thought there might be plugs you could get to cut there own threads or stay tight once in.
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muddymesser
Mud Obsessed


Joined: 17 Jun 2008
Odometer: 7819
Location: preston



PostPosted: Thu Sep 06, 2012 6:00 pm    Post subject: Reply with quote

could you tap it out to fit a bigger plug ?
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ecoast
Gate Opener


Joined: 05 Feb 2012
Odometer: 29
Location: The Highlands of NNJ; USA



PostPosted: Thu Sep 06, 2012 6:14 pm    Post subject: Reply with quote

it's just the filler plug; can you not use some sealant and thread it in?

no pressure from diff oil...

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horsethief
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Joined: 22 Dec 2009
Odometer: 502
Location: Ashton under Lyne



PostPosted: Fri Sep 07, 2012 3:13 am    Post subject: Reply with quote

Been using ptfe tape and sealant,but it seems a bit looser now as had to do oil when I changed the seals and there's not enough meat on the case for a bigger plug,
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stuckinmuck
Winch Assistant


Joined: 30 Mar 2012
Odometer: 86
Location: Exeter, Devon


1994 Suzuki Samurai

PostPosted: Fri Sep 07, 2012 9:40 am    Post subject: Reply with quote

What about removing the plug, drilling a smaller hole in the centre and tapping a thread for a bolt etc, then screwing the plug into the original thread and welding around the outside? I know it'll be a little more effort to put the oil in, but it'll be sealed up then, and not sure if its a level plug too but as long as you have the correct capacity to hand, it'll be fine.
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mnl
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Joined: 10 Nov 2001
Odometer: 826
Location: West Midlands



PostPosted: Sat Sep 08, 2012 11:33 am    Post subject: Reply with quote

Try this:

Completely degrease the plug & hole.

Fill the plug with metal loaded epoxy/chemical metal.
Drill right through, and tap m10 or m8
flatten the end of the plug on the outside to seal against.

Glue the plug in with chemical metal, build up around the outside to the casting if possible.

It will never come out now.

Fill through the m10 hole, and screw in an m10 bolt with a rubber or fibre seal against the flattened off plug.
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