Salisbury Diff Filler

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sp00k

sp00k

Well-Known Member
Posts
1,530
Location
Washington, County Durham, UK
Bugger! Noticed a drip from my rear Salisbury axel. I suspected it was from the filler plug as that area was a little damp. I released the plug which was very difficult all the way out. That gave me a bad feeling :( Once out, I checked the level which was fine.

When I screwed the filler plug back in, it was very easy to turn, all the way until it either fell into the diff :eek: or into the diff guard, I'm not sure which as I was not looking at the time. It may well be in the guard, but I'll have to take it off or see it in the light to be able to tell.

Either way, the thread or surround is obviously stripped/damaged. What's the best recommended repair - could I get a nut welded on? Tap it bigger? I don't think I would trust PTFE tape.
 
I had similar problem but mine fell out. Nothing there to tap so have to replace. I bodged mine with a back plate from a tap stuck on with chemical metal then using a male end cap screwed into it. Holding up so far.
 
Thanks for that guys. The beast has served me well and I don't want to chance a bodge, so it will be the proper fix of a new cover.

Is a new gasket or RTV recommended?

Thanks.
 
My parts have arrived. A couple of further questions:

The gasket looks like it's cork. Should I put a thin smear of blue Hylomar on it or just oil it?

The replacement diff cover comes with a plastic filler plug. Should I retain it or replace it with my original metal one?
 
not oil just very thin smear of hylomar and let it set , if you fit gasket wet it can squash out and split, metals better,but a lip to tighten against instead of taper is better still
 
Cheers Station House. Turns out, it was not plastic. It's actually metal, but not quite as substantial as the original filler plug. It's also hex shaped but much larger than any of my drivers, so I removed and reinserted it using the head of a large bolt. I've just stuck with it and it seems to be doing the job.
 
Me too! I've been really busy lately, so not had much time. I fitted the new cover yesterday and it seems to be working a treat. I did not have the adapter I would need to use a torque wrench so I just tightened the bolts by feel. The guide is only 22 NM (cover to axle), so I've been careful to not go mad. I left it overnight and drove it today with no visisble leaks.

I've left my diff guard off for now so I can keep an eye out for leaks. The plan is to spray it with underseal and get the guard back on at some point over the next few days. I'm not planning any offroad trips, so it's not critical when it gets done.

Being ex-mod, it was interesting to see the white paint peering through on areas of the old diff cover and bolts where I dislodged the underseal. The (working) convoy light is also still in place :)
 
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