dif drain plug idea...

mikeny59 · Sep 13, 2006

Friend bought an '06 xterra, rear dif has an allen-type drain plug, maybe front dif, too.

I know it's good to pull the dif cover to inspect innards, but putting that wise notion aside, will drilling and tapping a drain hole, let's say the size of the oil or tranny pan bolt hole (but using an allen set-screw type of bolt for clearance purposes) significantly weaken the housing?

Thanks,

Mike

jeepnuts311 · Sep 13, 2006

i also want to know the answer to this question.
i plan on using a spare D30 stock housing and beefing it up with steel. i planned on drilling a small hole, welding a nut in the hole and makin a drain plug.
i thought about tapping threads, but the metal isnt very thick.

-Tim

Root Moose · Sep 13, 2006

It's been done. I've seen it on D44s and D60s.

I have yet to hear anything negative.

I'd be leary to do it with a front 30 housing. They are weak enough as it is.

IntrepidXJ · Sep 13, 2006

ruffstuff does them, too

RichP · Sep 13, 2006

Personally I would go for the clear covers, some led's inside tied to your sound system and call it good.

All kidding aside I think the clear covers are good and cool looking but they are damn expensive considering they are formed and nothing more than a strong plastic cover. I know I have seen some D30 and 8.25 covers that are heavier and have both fill and drain but that was a couple or three years ago, have not looked for any since.
If I did go the plastic route I'd spring for say a warn diff guard or something though.

Dan Fredrickson · Sep 13, 2006

I wouldn't try it with anything less than 3/8", 1/4" dosen't like to hold threads very well when done by hand. We are using 5/16" Allen cap head bolts with a rubber bonded washer, the rubber compresses to form the seal, the 3/8" cover is tapped by machine before it is bent to get the best threads. It tucks down low protected by the ring and the mass of cover in the valley between, Pics tommorrow night, but it works very well.

Good time for that question since we joined today and just added it as a $5 option to our covers.

Dan Fredrickson

ChicksDigWagons · Sep 13, 2006

If I'm reading correctly I'm guessing you're talking about drilling and tapping a hole in the bottom of the actualy differential housing - NOT the cover, correct? Not sure where this talk of plastic covers of diff covers came from unless I totally misread your post... lol. Its been known to happen.

I personally don't think its a bad idea at all if you can get the cast to tap worth a damn. I'd be more worried about leakage and/or mangling the plug before I'd worry about the housing being weakened.

mikeny59 · Sep 13, 2006

I'm referring to the housing directly, I've been looking for correct sized set screws all over the place w/no luck.

Thinking about just getting a replacement for an '06 xterra and buying a tap/bit for that metric size.

Thanks for replies so far,

mike

Dan Fredrickson · Sep 13, 2006

Try a tapered pipe plug, you can get them in as small as 1/4" diameter. That way you wouldn't have to bottom the hole so the plug can't just screw all the way in......

Dan Fredrickson · Sep 14, 2006

Gravel Maker said:
I wouldn't try it with anything less than 3/8", 1/4" dosen't like to hold threads very well when done by hand. We are using 5/16" Allen cap head bolts with a rubber bonded washer, the rubber compresses to form the seal, the 3/8" cover is tapped by machine before it is bent to get the best threads. It tucks down low protected by the ring and the mass of cover in the valley between, Pics tommorrow night, but it works very well.

Good time for that question since we joined today and just added it as a $5 option to our covers.

Dan Fredrickson

Heres the pic I promised, you can see we don't spend alot on fancy pics.....the plug is tucked down in the valley where very few rocks go, protected by the diff ring and the rise in the cover.

Very simple and stout, I have seen it done before on 1/4" covers but they tapped them by hand and weren't happy, 3/8" is thick enough to get more than 3 threads on the bolt. The bolt is a 1/4" x 3/8" so it ends flush with the inside of the cover.

Dan Fredrickson
www.ruffstuffspecialties.com
Your Fab Parts Specialist
916.600.1945

dif drain plug idea...

mikeny59

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jeepnuts311

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Root Moose

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IntrepidXJ

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RichP

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Dan Fredrickson

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ChicksDigWagons

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mikeny59

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Dan Fredrickson

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Dan Fredrickson

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