97 EB Mike
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- Joined
- February 19, 2010
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- 165
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- City, State
- Ohio
- Year, Model & Trim Level
- 97 Eddie Bauer
Working on a 94 for a friend of mine. This truck has lived its entire life in the rust belt, and the rear diff plug simply isn't coming out with a 3/8 drive tool. I have a few ideas, and would like the opinion of someone with more experience.
Idea 1: drill out the fill plug and remove with an easy out/reverse drill bit/whatever works. The problem I see here is damaging the ring gear or getting a hole in the plug and still not being able to remove it.
Idea 2: Weld a small piece of steel in an open cavity on the back side of the cover, then drill and tap it to accept a plug/gasket combo similar to an oil pan plug. The problems I see here are: having to fill based only on the known capacity instead of filling until it drips out, the steel welded on the inside of the pan interfering with the gears/bearings in the diff, and burning holes in the cover when trying to weld a piece of steel in it.
Idea 3: Fill the diff through the vent tube based on known capacity. The problem I see here is potentially shoving a bunch of dirt/rust/other impurities into the diff oil, and having to fill based only on known capacity.
I know there are aftermarket covers available that have plugs in them, but I have not found one that is cost effective. If anyone has any better ideas, other potential problems with my ideas, or any thoughts in general, I'm all ears. Sorry for the long post, and I thank you for your time.
Idea 1: drill out the fill plug and remove with an easy out/reverse drill bit/whatever works. The problem I see here is damaging the ring gear or getting a hole in the plug and still not being able to remove it.
Idea 2: Weld a small piece of steel in an open cavity on the back side of the cover, then drill and tap it to accept a plug/gasket combo similar to an oil pan plug. The problems I see here are: having to fill based only on the known capacity instead of filling until it drips out, the steel welded on the inside of the pan interfering with the gears/bearings in the diff, and burning holes in the cover when trying to weld a piece of steel in it.
Idea 3: Fill the diff through the vent tube based on known capacity. The problem I see here is potentially shoving a bunch of dirt/rust/other impurities into the diff oil, and having to fill based only on known capacity.
I know there are aftermarket covers available that have plugs in them, but I have not found one that is cost effective. If anyone has any better ideas, other potential problems with my ideas, or any thoughts in general, I'm all ears. Sorry for the long post, and I thank you for your time.