What's wrong with this pic?

[Bart]

Found this yesterday when I went to pull my diff cover, fix the leak and install my new diff cover made from 3/8s. I am pissed and not quite sure what to do.

The two mounting holes on the bottom right are gone and the material has been shaved so they can't be added again. What would you do? I knew it was shaved but had no idea it didn't have the 2 mounting holes.

My bad for not paying closer attention but who does this kind of work? The first sign of trouble was finding the diff cover had been welded to the pig on the bottom. It leaked about a quart a month so there was no way I was leaving it.

Again, any suggestions would be appreciated. The second pic is the new diff cover marked with the material I'd have to remove to fit it. I just don't don't feel good about hoping it won't leak with the bottom two holes marked in red being 9.5 inches apart.

 

[James K]

it looks like there is enough material to tap it for quarter inch holes but diffently not enough for 3/8.

mod the cover with some tube to allow for the new bolts and you should be fine. JMO.

 

[Tacoma]

I probably wouldn't have shaved so much off.

I've seen some of the pirates using small bolts tapped into that thin diff area... but obviously you need a lip on the cover to do that....

 

[I Lean]

Weld a block of steel on the inside, tapped for a bolt--then a little recessed tube into the cover to hold the bolt. (make sense?)

 

[RockMonkey]

Tap a couple pieces of tube, and weld those to the housing and run bolts through them.

or

Weld back on 1/4 or 1/2 inch plate and drill and tap it for bolt holes.

 

[Bart]

Weld a block of steel on the inside, tapped for a bolt--then a little recessed tube into the cover to hold the bolt. (make sense?)

I like this idea the best, but don't have the tools or skills to do it.

 

[James K]

I like this idea the best, but don't have the tools or skills to do it.

then what good are you, honestly.

 

[Badger]

Would it be worth it to cut the rest off the bottom of then plating the opening closed with some nice thick plate?

Like this

 

[sixb]

I like this idea the best, but don't have the tools or skills to do it.

If you know what size you want your block and what size and where your tapped holes are, I can probably help with that part.

 

[gijohn40]

get some really small headed bolts and weld them to the diff and put a nut on them from the otherside of the cover?

 

[Meat_]

RTV, it's all about the RTV

 

[jsudar]

^^^^ If you use the correct amount of RTV and it still leaks--forget about gear oil and run extra thick clay-based grease so it can't leak out.

 

[Crinco]

Just a thought, for more $ you could find a new center and replace what you have. Pressing the tubes would be the expencive part I would think.
To attempt a repair, some one could weld on a piece of strap-maybe 1"x3"x0.3875" to the flat area (on the bottom of the housing) where the two missing bolts are and then drill and tap. Steel would wear longer but it would have to be a good weld!
The smaller bolts is an idea, but they are going to break easy, then you have the same leaking problem.

 

[UNSTUCK]

Would it be worth it to cut the rest off the bottom of then plating the opening closed with some nice thick plate?

Like this

x2. This is a good time to do it the "right" way. Plus it gets you a little more clearance. You would need to to modify your cover, but it looks like you'll be modifying no matter what.

 

[JackKeslerCustoms]

RTV, it's all about the RTV

Meat and i wheel together. But if it's advice your looking for, Badger is an excellent source. (No offense Mike)

 

[rholbrook]

No fix is complete without DUCT TAPE. Come on, what are you all thinking?

 

[Meat_]

Meat and i wheel together. But if it's advice your looking for, badger is an excellent source. (no offense mike)

:greg:

 

[rholbrook]

You need to use a combination of James K's and Meat's ideas.

"It looks like there is enough material to tap it for quarter inch holes but diffinately not enough for 3/8. Mod the cover with some tube to allow for the new bolts and you should be fine. JMO."

"RTV"

Oh yeah, and Duct Tape with a little McGyver ingenuity.

Put your cover on, use a Sharpie and mark the cover so you know where to cut it. Weld in the holes on the cover that aren't used anymore and then drill and tap your cover and pumpkin with much smaller bolts closer together. You ought to be able to get 3 - 4 holes drilled and taped in there. You should be able to get a hole taped all the way down to the bottom on the right. If your cover is just s tad shorter on the bottom it shouldn't get pulled apart as you drag it over rocks.

 

[XJEEPER]

Love the Ruffstuff 3/8" thick covers........
Try this for ideas http://www.4x4wire.com/tech/shaved60/ might be able to weld a piece of threaded DOM inside the punkin without tearing the diff apart..........maybe.

 

[Crinco]

Love the Ruffstuff 3/8" thick covers........
Try this for ideas http://www.4x4wire.com/tech/shaved60/ might be able to weld a piece of threaded DOM inside the punkin without tearing the diff apart..........maybe.

Wow that is some ugly welding on that plate they welded on. It's hard to get stick to look "pretty". But I like the four smaller bolt idea better