rear diff filler plug

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BeeBoy

BeeBoy

Member
Posts
85
Location
Co. Westmeath, Ireland
I have a 1983 series 3 swb. Its had some work done on it, which i am slowly having to redo for one reason or an other (fool and his money and all that).

Diff is leaking and need to replace gaskets etc, not to mention top up the oil levels, but.......there is no filler plug on my rear diff, and none on the axle casing/diff pan. The axle case was replaced, so assuming it is an older version.

Now, i need to do a bit of a bodge and create a filler plug on the diff pan - there was mention a long time ago on another form (can't find post) about drilling a hole and welding a nut on there. Anyone ever done this? How straight forward is this? Anything I need to be wary of? How far up the diff pan does this need to go?

All info gratefully received. thanks in advance.
 
Cheers for the reply, Dave.

been over every millimeter of the thing - theres no filler plug anywhere. think i've got a combination of mongrel parts - later diff and earlier axle case or visa-versa.

So, its either source a diff with filler plug, or likewise for axle case (not going to happen), or drill a hole and weld on a bolt that i can add a bolt to to creat a filler plug.
 
You could use a hydraulic bulkhead fitting with a blanking plug, something like a 3/4 male/male bulkhead adaptor sealed with a couple of 3/4 dowty washers, and capped with a blank plug.
Welding a nut on is probably better and cheaper if you need to remove the end cap.
 
It will be a lot more work, but if you're going to drill the diff pan then you should remove the diff first so that you can clean out the swarf. You don't want swarf ruining your bearings.
 
If yu are going to use it off road then replace the diff pan with a pipe cap (make sure it is not cast) they are like 5mm thick and yu will never need any more protection. you can tap it for a filler plug at the same time.
 
Industrial maintenance suppliers such as eriks or atlantic industrials, or a fire sprinkler suppliers, as well as nasty cast ones there are a lot of malleable iron ones which might as well be made from lead.
 
Hi,

Drain all the old oil out.

Use jack to tilt truck towards one side.

Remove halfshaft (5 bolts ... or is it 6?) Expect oil to drip/pour from bearing as you break the gasket seal. You don't even have to remove the wheel, but its a cleaner job if you do.

I think front diff has filler plug on axle case, rear diff has filler plug on diff case. Probably because its difficult to remove front halfshaft to pour oil in.

602

Pour in measured quantity of oil, through end of axle.
 
Thanks for the replies Chaps - much appreciated.

It doesn't get used in anger off road, just a bit of field work collecting timber and other bits and pieces, so serious protection of the diff is not really an issue.

That said, I got given a diff guard from a ninety yesterday (pick it up on monday) - would that fit?
 
Will it fit - most likely if it is the clamp-round type, but if you dont need it, dont fit it. They collect mud and ****e between the diff pan and the guard and it rots the pan thro in next to no time.
 
Do you know what ratio they your diffs are? The only ones I have come across without a filler in the nose of the diff were early Range Rover fronts. Every Series (Rover) diff I have seen has had a level plug eventthough it doesn't need in at the front.
 
early series 2 diff,

DSC00400.jpg
 
Thanks all for the advice - really very much appreciated.

In the end i've decided on the drill and tap method.

Yesterday the diff was removed (Jaysus they are heavy when your lying on your back under the landrover) and new filler plug created with felt washers.

Today, I'm coming to the end of a four day stint of work, that has seen swilvel ball seal, bearings and axle seals/Gaskets stripped and replaced, and back axle stripped, seal's/Gaskets replaced and Diff operated on.

Now, after a few more bits and pieces have been sorted and it's been for its test i may just get a few miles of fun out of the thing before the next disaster eats up more of my precious Annual Leave entitlement. That said, four of the bests day fun i've had in a long time!!!!
 
yeah, im at it with the spanners on the series2 every day im off work,

them diffs are a heavy lump int they ;) always drop it on yer chest not over yer head :D:D
 
Cheers, Truckcab.

Apparently, according to the wife, if i had dropped it on my head there would be less damage done than dropping it on any other part of the body!!!!!!!

:eek:
 
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