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Ready to begin the process. You can see I had already started a pilot hole, it's to the right of the large access hole.
Ready to begin the process. You can see I had already started a pilot hole, it's to the right of the large access hole.
0 2014/03/13 08:33:53
Safety first, covered the fuel tank with plactic to prevent rogue sparks from the hole saw going where I didn't want them. I also disconnected the negative post of the battery. A few extra minutes, with no regrets.... some things you don't get a do-over.
Safety first, covered the fuel tank with plactic to prevent rogue sparks from the hole saw going where I didn't want them. I also disconnected the negative post of the battery. A few extra minutes, with no regrets.... some things you don't get a do-over.
0 2014/03/13 08:33:53
1 1/2" All Metal hole saw bit. Place a little oil on either the bit edges or surface being cut to reduce heat/extra spark. With an all metal bit, you'll be done in about three seconds.
1 1/2" All Metal hole saw bit. Place a little oil on either the bit edges or surface being cut to reduce heat/extra spark. With an all metal bit, you'll be done in about three seconds.
0 2014/03/13 08:33:31
The differential fill plug is clearly visible. My camera angle is to the right of the hole, so it appears there is more clearance on the left side than there actually is, thus I should have cut the hole slightly more to the left.
The differential fill plug is clearly visible. My camera angle is to the right of the hole, so it appears there is more clearance on the left side than there actually is, thus I should have cut the hole slightly more to the left.
0 2014/03/13 08:33:31
Cut the new access hole to remove the differential fill plug. If i had a do-over, I would have moved the hole about a 1/2" to the left. I sprayed a little primer on the new cut to cover the exposed metal.
Cut the new access hole to remove the differential fill plug. If i had a do-over, I would have moved the hole about a 1/2" to the left. I sprayed a little primer on the new cut to cover the exposed metal.
0 2014/03/13 08:33:31
I used a 6". 1/2 extension to remove the plug. You can see I was right up against the left side of the hole. You don't need any socket on the end, just the extension. The extension end fits into the differential filler plug socket. Use a 3' extension to remove the differential drain plug, except reverse the extension and use either a 1/2' open end wrench or a vice grip placed at the socket end of the extension. The Haynes manual makes reference to needing a "special pipe plug socket", this isn't necessary when utilizing the 1/2' extensions.
I used a 6". 1/2 extension to remove the plug. You can see I was right up against the left side of the hole. You don't need any socket on the end, just the extension. The extension end fits into the differential filler plug socket. Use a 3' extension to remove the differential drain plug, except reverse the extension and use either a 1/2' open end wrench or a vice grip placed at the socket end of the extension. The Haynes manual makes reference to needing a "special pipe plug socket", this isn't necessary when utilizing the 1/2' extensions.
0 2014/03/13 08:33:01
This is the top view of a device called an "Expand-Tite". It's basically a bushing between two large washers with a bolt to tighten. When tightened, the bushing is expanded to plug the newly drilled access hole.
This is the top view of a device called an "Expand-Tite". It's basically a bushing between two large washers with a bolt to tighten. When tightened, the bushing is expanded to plug the newly drilled access hole.
0 2014/03/13 08:33:01
This funnel has a one quart capacity, you need to add 2.2 qts to refill the differential. The funnel also has a valve at the base (blue part) that you can open once you've filled the funnel. The hose has an outside diameter of 3/4". I replace the hose that came with the funnel because it was a little short and I didn't want it coming out of the fill hole with the when I opened the valve. Having the valve allows you to have both hand available, one to secure the hose, the other to open the valve.
This funnel has a one quart capacity, you need to add 2.2 qts to refill the differential. The funnel also has a valve at the base (blue part) that you can open once you've filled the funnel. The hose has an outside diameter of 3/4". I replace the hose that came with the funnel because it was a little short and I didn't want it coming out of the fill hole with the when I opened the valve. Having the valve allows you to have both hand available, one to secure the hose, the other to open the valve.
0 2014/03/13 08:33:01
Differential filled and all buttoned up with the Expand-Tite plug.
Differential filled and all buttoned up with the Expand-Tite plug.
0 2014/03/13 08:32:22
Side view
Side view
0 2014/03/13 08:32:22
Bottom view
Bottom view
0 2014/03/13 08:32:22