Mangled rear diff drain plug. Best way to fix? (1 Viewer)

[2021 LC200]

Like the JB weld

 

[KLF]

This is the best way to fix this. Radical, but you'll never have to worry about bunging up the drain plug again.

Remove the axle housing from the truck. Plasma out the drain plug entirely.

Mount an empty diff housing to the axle. Plasma out the rest of the bottom of the axle.

Weld a plate over the opening. Test for leaks with brake clean. Paint and re-install.

Use the bottom diff studs to drain the axle in the future.

(did both axles in my mini in 2003)

 

[2021 LC200]

@KLF assume you went this route after severely damaging the factory drain plug and or using your 200 on serious Offroad tracks all the time?

 

[TeCKis300]

There will always be bigger rocks, but taller tires might be the answer if dragging the diff is a regular occurrence.

 

[2021 LC200]

I just saw the thread started with KLF having a leak from the diff plug during a MOAB trip. I see can see his motivation now.

I personally want to keep replacing the TC and Diffs oils relative easy every 30 to 50k miles so once I mod my 200 for more serious off-roading (which would include larger diameter tires…) I think I get the metal ring and use probably a combination of set screws and JB weld to mount the same.

 

[KLF]

@KLF assume you went this route after severely damaging the factory drain plug and or using your 200 on serious Offroad tracks all the time?

This was on my '87 Xtra cab pickup that I was gradually building up as a crawler in the early 2000's. I eventually did a frame-off on it, this truck lives somewhere in southern AZ now.

 

[prharper]

Did you weld it on yet?

Any learnings?

Any pictures?

Thanks in advance

Not yet.