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Need the O.D. size of both transfer case and differential fill holes

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Old Apr 29, 2017 | 12:27 PM
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Dell Gailey's Avatar
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Question Need the O.D. size of both transfer case and differential fill holes

Trying to mock up and buy a manual or electric pump to evacuate (through fill/level plug holes) and then fill each. Would appreciate this info, if anyone knows it off the top of their head so I don't purchase a unit with too large a tube to insert into the apertures (or be ready to retro fit to correct diameter).

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Old Apr 29, 2017 | 03:38 PM
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Both have 1/2 inch BSPT (British Standard Pipe Thread Taper) fittings. As you're in the US, 1/2 inch NPT (National Pipe Taper) will do (the difference is that BSP has a Whitworth thread form - 55 deg while NPT uses 60 deg. Both are 14 TPI (Thread/Inch).

Note that the plug in the diff is a fill/level plug, but in the transfer box, what appears to be a level plug is actually a drain plug. The trouble is that it's set so high that 250 mls of oil are left in the box. Draining it with a suction tube is difficult - the internals are close up to the the drain hole.

One solution to filling the box is to tilt the car by lifting left hand side sill 540 mm then put in 400 mls of 75W 140 oil. If you didn't drain the box completely, you may not get that much in.

Note also that the original fill quantity was 550 mls, but that was progressively reduced by Jaguar as too much oil was being blown out through the breather on top of the box. That oil runs down the right hand side of the box and looks like a failed driveshaft seal.

The diff takes the same oil as the transfer box.
 
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Old Apr 29, 2017 | 05:12 PM
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Thanks astrmorg, looks like what I'm looking at will work.
Response from mfg = Thank you for giving JEGS the opportunity to assist you with your technical question.

This kit uses 5/16 hose so you should not need to make modifications to fill your transfer case or differential as its made primarily for that reason.
 
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Old Apr 29, 2017 | 09:47 PM
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That pump will prolly work on differential, but you'll not be able to get the tube into the transfer case. There's not enough clearance from the gears. I have the t-shirt.
 
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