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#Post#: 59038--------------------------------------------------
How to fit a filler plug to a diff
By: Lurch Date: April 28, 2013, 8:03 am
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Ive done this a few times now including today so here's an
idiots guide to drilling and tapping a diff casing
Not meant to be patronizing i will assume you have never tapped
a hole before or used a drill much.
So, firstly take one diff and support it preferably on a bench
so that the area we are drilling into is level, the diff wont be
in its "as fitted" position (nor will it be in the spazzed
position shown,photofucket doesn't seem to want me to turn any
of the pics in this post ,the drill is actually upright
:banghead)
Then, centre punch the exact spot we intend to drill through,
place some clean rag inside the diff to collect most of the
swarf but don't put it up against the area yhe drill will come
through,otherwise you will have a tangled mess of drill,rag and
swarf in your diff.
Drill a pilot hole taking care to be upright and square to the
drilled surface, you don't need a pillar drill for this job, i
used a hand held drill with a 4.5mm bit, let the drill do the
work
HTML http://i308.photobucket.com/albums/kk329/lr229/Photo0112_zpse4d95209.jpg
I then upped my pilot to an 8.5 and redrilled the hole, you can
use any amount and size pilot drills, the idea is to simply
remove metal before
the final drill,which in this case is an 11.8mm bit.
Bear in mind the larger the bit the slower it needs to turn to
cut well,so reduce the speed as you go up the sizes.
Once the 11.8 has been through you are ready to tap a thread,
taps usually come in sets of three, the most tapered is your no.
1 tap, the flatest your last
I am tapping this hole with a 1/4 BSP thread, i didn't have a
tap holder big enough for this tap so had to wing it with a 1/4W
openender
not ideal as a tap holder helps with lining it up and applying
equal pressure.
Anyhow, take your time and set this 1st tap off square, the diff
is fairly thick and you don't really want to be doing more than
a quarter of a turn forward and back once its started,cutting
compound is a bonus but i used a bit of WD.
Wind the tap fully in using the 1/4 turn method,don't overdo it
as taps are brittle and can snap causing major arse pain.
I didn't have a secondary tap so went straight for the final,
you can safely wind this tap in a whole turn in and half a turn
back until its all the way in.
HTML http://i308.photobucket.com/albums/kk329/lr229/Photo0117_zps286bea54.jpg
Not sure if you can make out the longer taper on the tap on the
bottom this is no.1 or primary
HTML http://i308.photobucket.com/albums/kk329/lr229/Photo0124_zps8c2a4bb4.jpg
Stick a bit of ptfe round the plug threads or a crush washer
under your plug and tighten with a 17mm spanner, carefully
remover rag,rinse out diff and refit
Piece o piss :thumbs:
HTML http://i308.photobucket.com/albums/kk329/lr229/Photo0122_zps4757ffcd.jpg
#Post#: 59075--------------------------------------------------
Re: How to fit a filler plug to a diff
By: RMS Date: April 28, 2013, 12:34 pm
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Good tutorial Lurch.
I've done a few of those myself, though I use an M12 tap (10.5mm
drill) & M12 bolt with fibre washer as they are what I've got
laying around :thumbs:
#Post#: 59340--------------------------------------------------
Re: How to fit a filler plug to a diff
By: mr.scruff Date: April 30, 2013, 7:16 am
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Metric...? :haha:
Good stuff Lurchington :thumbs:
#Post#: 59354--------------------------------------------------
Re: How to fit a filler plug to a diff
By: RMS Date: April 30, 2013, 9:49 am
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[quote author=mr.scruff link=topic=5373.msg59340#msg59340
date=1367324174]
Metric...? :haha:
[/quote]
As I say, it's what I've got laying around.
I don't particularly want to buy 1/4" BSP taps and plugs when
I've already got stuff that will do.
Anyway, the diffs are from a metric vehicle so there goes
originality :rolleye0012:
#Post#: 59361--------------------------------------------------
Re: How to fit a filler plug to a diff
By: stevej Date: April 30, 2013, 10:57 am
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I like it, Need to do mine. Makes it far easier to fill the oil,
just dont know if I can be arsed taking it off again. Should
have done it in the first place :smiley-furious:
#Post#: 59366--------------------------------------------------
Re: How to fit a filler plug to a diff
By: mr.scruff Date: April 30, 2013, 11:20 am
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I am jesting RMS. I don't think there's an imperial fixing left
under my bonnet except for the engine mount bolts. :thumbs:
#Post#: 59371--------------------------------------------------
Re: How to fit a filler plug to a diff
By: RMS Date: April 30, 2013, 11:28 am
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[quote author=mr.scruff link=topic=5373.msg59366#msg59366
date=1367338804]
I am jesting RMS. I don't think there's an imperial fixing left
under my bonnet except for the engine mount bolts. :thumbs:
[/quote]
:thumbs:
#Post#: 61755--------------------------------------------------
Re: How to fit a filler plug to a diff
By: stevej Date: May 21, 2013, 10:43 am
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Im on with fitting a plug now. There doesnt seem to be a lot of
room on the disco diff, has anyone fitted one to the diff pan
like the one on the front? If so then why not it looks easier
and there is no chance of getting bits of metal where you dont
want it?
#Post#: 61757--------------------------------------------------
Re: How to fit a filler plug to a diff
By: RMS Date: May 21, 2013, 10:51 am
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That's where the filler is supposed to go on the Salisbury, on
that flange.
If you've swapped it, you should be able to compare it with the
old one.
Of course you can fit a filler on the diff pan, but you'll have
to weld/braze a nut or boss or something to the pan, and make
sure there are no pinholes in your welding/brazing!
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