ctjkelley

Has anyone found a good way to add a fill plug to a stock 8.8 diff. I'm trying to save money and not by an aftermarket on.

SeriousOffroad

What's wrong with buying a quality aftermarket cover to replace the flimsy OEM cover?

ctjkelley

It's pretty clear in my post that I'm trying to save money and NOT buy an after market cover. I can use the money in other places.

SeriousOffroad

Yes you did and I asked why?

The stock cover is thin and not worth the time and effort to modify.

And what's wrong with the existing fill hole?

Lowrange2

A stock 8.8 doesn't have a fill hole in the cover.

They expect you to fill it thru the speed sensor hole in the top of the housing.

ctjkelley

I just like the fill hole that's on the 8.25, and as to why,they are way over priced in my opinion. I just don't need it

SeriousOffroad

I know that.

It's easy to get to.
One bolt to remove the sensor.

Why re-invent the wheel?

SeriousOffroad

You'll change your mind once you peel the diff cover open on a rock....and you will.

Lowrange2

Ah, I misread.

I thought you were suggesting there was a fill hole in the cover...

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I do have to agree, I won't wheel rocks with a stock cover. I can't count the number of times that a real cover has saved my day.

ctjkelley

Why is my thread getting crashed by a vendor telling me what I should do. If I wanted a new diff cover I would buy one. It's a mod question not inquiring about a new diff cover question.

jmu427

Here is something that worked when I added a blower to my old Mustang. The oil line to the blower needed a drain back to the oil pan. As per the installation instructions, and to do this without having to drop the pan a weld in a bung, I:

1. Punched a hole in the pan. (Take a punch and drive it alll the way through the metal. When you do this the metal should split and be driven in towards the direction you are hammering);
2. Threaded the metal folds that went in towards the pan (when you punch the hole, obviously try to size it close to the same size as to what you will be using for a threaded plug);
3. Screwed in the fitting for the drain line

I used a little RTV on the threads when in stalled the fitting and never had a leaking issue. Might be worth a shot here if you have the tools.

planewrench

Mine has a fill plug at the front of the housing just to the left of the pinion. aren't they all like that?

ctjkelley

All that I have seen are like that I just like the plug on the diff cover.

SeriousOffroad

No one told you to do anything. You're free to do what ever you want to. I'm suggesting a different course than the one you're on because it will benefit you in the long run.

There are plenty of low-buck options out there.

emptypockets

Hole saw and a rubber plug? Hole saw and weld in a threaded insert? I'm about as cheap as they come, but even I would recommend buying an aftermarket diff cover if you do any sort of wheeling.