fill plug relocation - Pirate4x4.Com : 4x4 and Off-Road Forum

buford · 08-07-2002, 05:57 PM

I did a search on this already, so here goes. On all the SOA write ups I have not seen anyone mention relocating the fill plugs for the diff....shouldn't this be done??

KeithF · 08-07-2002, 06:26 PM

Why would you want or need to relocate the fill plug? If the pumpkin/pinion is rotated up just park up or down hill to level it out while filling up.

or maybe there's more to it than that and I'm just

BJ On Roids · 08-07-2002, 07:03 PM

medusa
his webpage

green forty series

fill plug relocation is mentioned

cruiserbrett · 08-08-2002, 07:51 AM

Most SOA setups with rotated axle housings have them rotated quite a bit, mine will be about 30 degrees, and that is a LOT of difference in oil volume. It would take a pretty steep hill or a really tall hilift to fill it, and then filling in an emergency would be a short fill, not something I want with the pinion bearing that high up in relation to its original 'nearly at oil level' location.

All you need is a pair of hole saws and a piece of metal to plug the hole where the plug used to be...

KeithF · 08-08-2002, 08:20 AM

I live in SF so 30 degrees ain't nothing around here

Medusa · 08-08-2002, 08:35 AM

The way I did my FJ40 axle fill plugs was to cut a rectangular section about 1.5" wide and 3" long out of the diff cover. The original fill plug was located at the bottom of this rectangle. When removed, simply rotate the piece 180* so that the fill plug is not at the top of the hole and weld it back in. Grind off the welds, sand and paint and you can't tell that the plug was even moved

Tankota · 08-08-2002, 03:24 PM

I had a bent housing I was swapping out when I did the pinion rotation so I cut out the fill hole and welded it into my new housing further up the face. I also cut out the entire bottom half of the face and welded that to my new front diff for some armor from rocks that kept on denting my old housing.

For my rearend (dana 60) I welded a nut to the inside of the cover and used a short bolt for a plug (with the correct kind of washer).

I have 4 fill plugs on my 2 diffs

wngrog · 08-08-2002, 08:10 PM

My diff is at a pretty wicked angle and I just jack the rear up with floorjack under the rear and over fill it.

Not had a problem yet.

rustyb · 08-12-2002, 12:39 PM

Hey Nolen, as often as you turn your rig on its side now, you could just take advantage of it and give the old diff a fill up before laying her back over.

wngrog · 08-12-2002, 02:50 PM

Crawl back under your rock and don't come back out until you can wheel/weld again

GhettoRig · 08-12-2002, 03:38 PM

The fill plugs are just 1/2" NPT (dana 60 ones, anyway). You can weld an extra layer of metal somwhere on the cover, then drill and tap it for the new plug.

08-07-2002, 05:57 PM	#1 (permalink)
buford Registered User Join Date: Jul 2001 Member # 5967 Location: Baton Rouge, LA Posts: 94	fill plug relocation I did a search on this already, so here goes. On all the SOA write ups I have not seen anyone mention relocating the fill plugs for the diff....shouldn't this be done?? __________________ Buford '78 FJ40,4.88s, loc-rites,39.50 TSLs, front & rear winches custom 6 point cage,V8 sm465, toy box, splitcase on the way. "If at first you don't succeed......weld it up and try again" [URL=www.tlcconcepts.com]www.tlcconcepts.com[/URL]

08-07-2002, 07:03 PM	#3 (permalink)
BJ On Roids Registered User Join Date: Aug 2001 Member # 6588 Location: 'Straya....mate Posts: 7,434	medusa his webpage green forty series fill plug relocation is mentioned __________________ [COLOR=yellow]Bj on Roids 1970FJ45, Quad Cam V8, Auto, Broken T-case, H-TEC (traction control and cutting brakes) 42 TSLs.[/COLOR] [COLOR=green][URL=http://www.outerlimits4x4.com]Aussie Wheelers Bulletin Board[/URL] [/COLOR]

08-08-2002, 07:51 AM	#4 (permalink)
cruiserbrett Registered User Join Date: Sep 2001 Member # 6863 Location: San Diego Posts: 2,797	Most SOA setups with rotated axle housings have them rotated quite a bit, mine will be about 30 degrees, and that is a LOT of difference in oil volume. It would take a pretty steep hill or a really tall hilift to fill it, and then filling in an emergency would be a short fill, not something I want with the pinion bearing that high up in relation to its original 'nearly at oil level' location. All you need is a pair of hole saws and a piece of metal to plug the hole where the plug used to be... __________________ I have enough projects for the next decade. Need two?

08-08-2002, 08:35 AM	#6 (permalink)
Medusa Old Rock Doc Join Date: May 2000 Member # 915 Location: Fargher Lake FrankenCruiser Lab Posts: 1,648	The way I did my FJ40 axle fill plugs was to cut a rectangular section about 1.5" wide and 3" long out of the diff cover. The original fill plug was located at the bottom of this rectangle. When removed, simply rotate the piece 180* so that the fill plug is not at the top of the hole and weld it back in. Grind off the welds, sand and paint and you can't tell that the plug was even moved __________________ Got Rice?

08-08-2002, 08:10 PM	#8 (permalink)
wngrog Moderating Midget Join Date: Jun 2000 Member # 1154 Location: Canton, MS Posts: 22,056 Blog Entries: 4	My diff is at a pretty wicked angle and I just jack the rear up with floorjack under the rear and over fill it. Not had a problem yet. __________________ Nolen Grogan 1997 FZJ-80 Land Cruiser, 37's 2010 RZR-4 www.cottonlandcruisers.com www.rockmidgetphotography.com USAF Veteran 1988-1998 GOD Bless America

08-07-2002, 06:26 PM	#2 (permalink)
KeithF Registered User Join Date: Feb 2000 Member # 270 Location: Tahoma, CA Posts: 2,454	Why would you want or need to relocate the fill plug? If the pumpkin/pinion is rotated up just park up or down hill to level it out while filling up. or maybe there's more to it than that and I'm just

08-08-2002, 08:20 AM	#5 (permalink)
KeithF Registered User Join Date: Feb 2000 Member # 270 Location: Tahoma, CA Posts: 2,454	I live in SF so 30 degrees ain't nothing around here

08-08-2002, 03:24 PM	#7 (permalink)
Tankota Registered User Join Date: Jun 2000 Member # 1159 Location: Olympia, WA Posts: 1,861	I had a bent housing I was swapping out when I did the pinion rotation so I cut out the fill hole and welded it into my new housing further up the face. I also cut out the entire bottom half of the face and welded that to my new front diff for some armor from rocks that kept on denting my old housing. For my rearend (dana 60) I welded a nut to the inside of the cover and used a short bolt for a plug (with the correct kind of washer). I have 4 fill plugs on my 2 diffs

08-12-2002, 12:39 PM	#9 (permalink)
rustyb Registered User Join Date: Jul 2000 Member # 1357 Location: St. Francisville, La. Posts: 599	Hey Nolen, as often as you turn your rig on its side now, you could just take advantage of it and give the old diff a fill up before laying her back over. __________________ 77 FJ40, 5.7L vortec, soa, shaved 14 bolt rear, stock front housing loaded with some good stuff, and a lot of f***ing dents and rust.

08-12-2002, 02:50 PM	#10 (permalink)
wngrog Moderating Midget Join Date: Jun 2000 Member # 1154 Location: Canton, MS Posts: 22,056 Blog Entries: 4	Crawl back under your rock and don't come back out until you can wheel/weld again __________________ Nolen Grogan 1997 FZJ-80 Land Cruiser, 37's 2010 RZR-4 www.cottonlandcruisers.com www.rockmidgetphotography.com USAF Veteran 1988-1998 GOD Bless America

08-12-2002, 03:38 PM	#11 (permalink)
GhettoRig Registered User Join Date: Mar 2001 Member # 3774 Posts: 369	The fill plugs are just 1/2" NPT (dana 60 ones, anyway). You can weld an extra layer of metal somwhere on the cover, then drill and tap it for the new plug.

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