Keyav8r Posted January 15, 2018 Share Posted January 15, 2018 There is no fill port on the body of the differential. The cover has a rubber plug that looks to be at the right full level. I’ve pried around on the edges but I’m concerned I’ll tear it up getting it out and then have no way to seal the differential. Is the hole possibly threaded so that the rubber plug can be replaced with a pipe plug? Any and all help will be greatly appreciated. Sent from my iPad using Tapatalk Link to comment Share on other sites More sharing options...
yxmj Posted January 15, 2018 Share Posted January 15, 2018 The rubber plug is your fill plug.....use a wide flat screwdriver or chisel (or2) pry it out... Link to comment Share on other sites More sharing options...
HOrnbrod Posted January 15, 2018 Share Posted January 15, 2018 Back when I had the D35 I tore the plug up a bit when removing. The hole was not threaded. I refilled it and reused the rubber plug, and it luckily didn't leak. But I did order a new cover with a real threaded bung and replaced the crappy original. Link to comment Share on other sites More sharing options...
Keyav8r Posted January 15, 2018 Author Share Posted January 15, 2018 Thanks to both of you. That’s what I thought, but it just looks cheap. Link to comment Share on other sites More sharing options...
DesertRat1991 Posted January 15, 2018 Share Posted January 15, 2018 I grabbed a new plug off Amazon when I serviced the diff. Slowly trying to replace all old rubber bits. Check out the pics, you can see it's just a barbed rubber plug. Pop it out. If it's old and brittle, yes it might tear. https://www.amazon.com/gp/aw/d/B007Q0DAXG/ref=mp_s_a_1_fkmr0_1?ie=UTF8&qid=1516047931&sr=8-1-fkmr0&pi=AC_SX236_SY340_QL65&keywords=dana+35+drain+plug Link to comment Share on other sites More sharing options...
Keyav8r Posted January 16, 2018 Author Share Posted January 16, 2018 There is allegedly a plug on the Help racks at auto parts stores. The O’Reilly website said they had them at my local store but the counter girl - excuse me - the counter person said not so. A nearby Advance Auto and a farther away Autozone supposedly have them according to their websites. I’d like to know the part was there before I drove there, but past experience tells me the response will probably be “I don’t think we got anything like that”. Link to comment Share on other sites More sharing options...
HOrnbrod Posted January 16, 2018 Share Posted January 16, 2018 I always call the store no matter what the website says and ask for the part using it's catalog number before I go. All the counter drones know how to do is look up something by it's part number. Link to comment Share on other sites More sharing options...
Keyav8r Posted January 19, 2018 Author Share Posted January 19, 2018 Picked up a new plug at Autozone for $2.99. Looks like I have a pinion seal leaking, so that’s my next project. It’s literally always something. I believe this must be a form of mental illness because I enjoy it. Link to comment Share on other sites More sharing options...
HOrnbrod Posted January 22, 2018 Share Posted January 22, 2018 On 1/18/2018 at 7:45 PM, Keyav8r said: Looks like I have a pinion seal leaking, so that’s my next project. When you change the seal, think about replacing the craptacular stock strap pinion yoke with a stronger u-bolt pinion yoke. You'll probably snap a strap bolt off anyhow removing it. Link to comment Share on other sites More sharing options...
Keyav8r Posted January 23, 2018 Author Share Posted January 23, 2018 I had it apart once when I was working on the fuel,pump and sender and managed not to break anything. However, I might not be so fortunate next time. I may have to replace the pinion yoke when I do the seal if it is grooved and might as well upgrade. Do you have a good supplier for the kit? Link to comment Share on other sites More sharing options...
HOrnbrod Posted January 23, 2018 Share Posted January 23, 2018 I used a Dana-Spicer kit when I did my D44. Paid about the same for it as THIS one. Link to comment Share on other sites More sharing options...
Keyav8r Posted January 24, 2018 Author Share Posted January 24, 2018 Thanks. May be a while before I get to it. Too many projects, too little time! Link to comment Share on other sites More sharing options...
youngfred Posted January 24, 2018 Share Posted January 24, 2018 On 1/22/2018 at 11:11 AM, HOrnbrod said: When you change the seal, think about replacing the craptacular stock strap pinion yoke with a stronger u-bolt pinion yoke. You'll probably snap a strap bolt off anyhow removing it. ... Is this a good candidate for a tech write up ? youngfred Link to comment Share on other sites More sharing options...
Keyav8r Posted January 25, 2018 Author Share Posted January 25, 2018 I would think of it more as a repair and an upgrade on the yoke. But, far be it from me to discourage you from doing a tech topic on it 😇. The tricky part of the change is properly re-torquing the pinion yoke nut without increasing preload on the pinion bearings. I think someone has done a write-up on the process but, if not, it’s covered in the service manual (and probably on Youtube). Link to comment Share on other sites More sharing options...
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