Metal obstruction on inside of front differential fill hole
#1
Metal obstruction on inside of front differential fill hole [solved]
2003 Discovery
I started to remove the front differential plastic fill plug in order to replace the leaky seal, but soon realized the plug was continually spinning and not coming out, even though the plug was past the threats. I eventually pulled it out successfully. I thought this to be strange, but figured I had somehow damaged the plug the last time I installed it.
I purchased bronze fill plugs and put no more thought into it until I received the bronze plugs and attempted to install them. Very soon after attempting to install the plugs, I noticed it became unusually difficult to spin, despite the threads being properly aligned. I removed the plug and looked inside the differential fill hole with a flashlight and noticed a small metal obstruction, similar to a metal glob caused from welding splatter, on the inside of the differential wall, partially blocking the hole and thus preventing the plug from inserting. I pulled on it with my finger, to no avail. I tapped on it with a screwdriver, again to no avail.
I have no idea what it could be or how it got there. Any ideas? My plan is to run a tap through the fill hole to clean out the obstruction. Any better ideas? Anybody know what size tap I should purchase?
Thanks.
I started to remove the front differential plastic fill plug in order to replace the leaky seal, but soon realized the plug was continually spinning and not coming out, even though the plug was past the threats. I eventually pulled it out successfully. I thought this to be strange, but figured I had somehow damaged the plug the last time I installed it.
I purchased bronze fill plugs and put no more thought into it until I received the bronze plugs and attempted to install them. Very soon after attempting to install the plugs, I noticed it became unusually difficult to spin, despite the threads being properly aligned. I removed the plug and looked inside the differential fill hole with a flashlight and noticed a small metal obstruction, similar to a metal glob caused from welding splatter, on the inside of the differential wall, partially blocking the hole and thus preventing the plug from inserting. I pulled on it with my finger, to no avail. I tapped on it with a screwdriver, again to no avail.
I have no idea what it could be or how it got there. Any ideas? My plan is to run a tap through the fill hole to clean out the obstruction. Any better ideas? Anybody know what size tap I should purchase?
Thanks.
Last edited by HopeItsNotAMoneyPit; 12-08-2021 at 09:41 PM. Reason: Solved
#2
#4
First what type of Tap will you use a starter tap,I would pack the tap with grease to try and prevent the metal piece from dropping inside, be aware that it the spatter is fast it may break the tap,
lastly have you measured the depth of thread you have and if so is it possible to cut down the new plug so it will go in with out removing the offending bit of spatter
lastly have you measured the depth of thread you have and if so is it possible to cut down the new plug so it will go in with out removing the offending bit of spatter
#8
#9
@HopeItsNotAMoneyPit I was thinking a PO used a metal plug and screwed it up then used a plastic one to make do