So, we are in trouble. Last week we removed the axle breather screw to give us more brake line flex while doing the lift kit. Now, when we try and put the screw back in, it will turn about 3/4 of a turn and then break, leading me to believe that the threads in the axle housing are screwed... I bought a new screw just to see if it was the original screw being the problem, but it wasn't, and now we are stumped. I've heard that we need to tap the threads, but I've never done that. How difficult is it and are there any other solutions? Thanks...

 

You can buy taps at most hardware stores. Take the axle breather with you to verify the correct tap. Some threads are tapered for sealing purposes. A knowledgable store worker should be able to hook you up with the right tap.
Before chasing the threads, smear some axle grease, on the tap, to catch metal chips. Start the tap in with your fingers making sure the tap is straight. Then use a tap handle or small wrench to do the rest.

 

Tapping the threads is easy, but you'll need a bigger screw to match the new threads. Just go buy a tap and die set (If you work on the Jeep at all you'll probably use the set multiple times) and follow the instructions. The other option would be to just epoxy or JB Weld it in place

 

So I got a new tap that is the same as the existing screw, 7/16 20. I'm planning on trying it tomorrow when I get the chance. Will I need to change my diff oil afterwards in case there are any shavings left over?

 

Like the previous poster said, putting a coating of grease on the tap should catch most of the shavings; either way, it certainly can't hurt to flush/refill your diff after doing this, and although I would do it, I wouldn't consider it necessary.

 

Ok, well the only reason that I wouldn't want to is that we did it about a month ago. We'll see how it goes tomorrow when we use the tap.

 

Everytime someone says "we" did something to a jeep I always think of some sort of team in an offroad shop lol

 

Haha, when I say we, I mean my roommate and I. We both have xjs and help each other out with projects.

 

Alrighty, just wanted to tell y'all thanks. The tap worked brilliantly, everything is together and we are back on the road. Thanks a ton!