<html><head></head><body><div style="color:#000; background-color:#fff; font-family:Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif;font-size:13px"><div id="yui_3_16_0_ym19_1_1504787121151_10698" dir="ltr"><span id="yui_3_16_0_ym19_1_1504787121151_10697">I have gone one step further and used studs in place of the bolts like used in many quick change rearends. It makes the in/out during set-up easier by reducing the times you have to run the bolt in/out of the threaded hole.</span></div><div id="yui_3_16_0_ym19_1_1504787121151_10698" dir="ltr"><span>JMTC</span></div><div id="yui_3_16_0_ym19_1_1504787121151_10698" dir="ltr"><span>Eclectic Ed</span></div> <div class="qtdSeparateBR"><br><br></div><div class="yahoo_quoted" style="display: block;"> <div style="font-family: Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif; font-size: 13px;"> <div style="font-family: HelveticaNeue, Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif; font-size: 16px;"> <div dir="ltr"><font size="2" face="Arial"> On Thursday, September 7, 2017 5:56 AM, Michael Porter via Fot <fot@autox.team.net> wrote:<br></font></div> <br><br> <div class="y_msg_container"><div dir="ltr">On 9/6/2017 6:04 PM, Jason Ostrowski via Fot wrote:<br clear="none">> Hey.<br clear="none">> Yeah... most of the diffs I have around have at least one thread hole <br clear="none">> screwed up somewhere on the thing.<br clear="none">><br clear="none">> I'm not sure this will work at the narrow edge area you are working on <br clear="none">> but I figure its on topic enough to mention...<br clear="none">> we have used something called A "Steel cert" or "Time sert" or "big <br clear="none">> sert" recently.<br clear="none">><br clear="none">> Perhaps many already know about these "better than a heli coil fix"<br clear="none"><br clear="none">These are variants on the name brand "KeenSert," which was originally <br clear="none">developed for repairs of stripped internal threads in aluminum and other <br clear="none">metals softer than steel:<br clear="none"><br clear="none"><a shape="rect" href="http://www.repairengineering.com/keensert.html" target="_blank">http://www.repairengineering.com/keensert.html</a><br clear="none"><br clear="none">The KeenSert uses hardened steel flat pins to positively lock the insert <br clear="none">into the softer metal, preventing it from rotating with the bolt, but I <br clear="none">don't think these can be used with harder materials like steel or cast iron.<br clear="none"><br clear="none">The problem I see in using what you've suggested is the need to <br clear="none">accommodate the locating sleeve. The sleeve doesn't so much resist side <br clear="none">forces as much as it serves to locate the carrier bearing cap, with the <br clear="none">retaining bolts providing the force to resist most of the movement of <br clear="none">the carrier bearing cap.<br clear="none"><br clear="none">That said, these fixes probably can be used if the correct cutter can be <br clear="none">found to create the recess for the sleeve. The setup would be a bit <br clear="none">tricky, but not difficult for an experienced machinist. It would <br clear="none">require finding a sharp hole saw sort of cutter (a shell mill) that had <br clear="none">an OD the same as the OD of the sleeve, indexing the part so that the <br clear="none">mill and cutter would be concentric and true to the old hole, then <br clear="none">drilling or milling the new recess for the insert, raising the mill bit <br clear="none">sufficiently to tap the hole for the insert, install the insert, and <br clear="none">then without losing the location, use the shell mill to cut the new <br clear="none">recess in the insert for the sleeve. This wouldn't have to be as deep <br clear="none">as the original so as not to lose too much thread on the insert. The <br clear="none">sleeve can always be turned down a bit if necessary to ensure it fits in <br clear="none">a shallower recess.<br clear="none"><br clear="none">If I couldn't find another good diff case, that's the way I'd do it. <br clear="none">But, truthfully, that's more time (that you're paying the machine shop <br clear="none">for) than fitting the gears to a replacement diff case, which, with the <br clear="none">right tools, doesn't take more than two or three hours to fit new gears <br clear="none">and set pinion depth and preload. Additionally, I don't think I'd want <br clear="none">to do any machining on an assembled unit, anyway--too many chips flying <br clear="none">around that might be difficult to remove after the fact, and could futz <br clear="none">up the works.<br clear="none"><br clear="none">If another diff is available, use that, and have the old case with the <br clear="none">stripped hole repaired at one's leisure.<br clear="none"><br clear="none"><br clear="none">Cheers.<br clear="none"><br clear="none">-- <br clear="none"><br clear="none"><br clear="none">Michael Porter<br clear="none">Roswell, NM<br clear="none"><br clear="none"><br clear="none">Never let anyone drive you crazy when you know it's within walking distance....<div class="yqt3420508064" id="yqtfd52314"><br clear="none"><br clear="none"><br clear="none">_______________________________________________<br clear="none"><a shape="rect" ymailto="mailto:fot@autox.team.net" href="mailto:fot@autox.team.net">fot@autox.team.net</a><br clear="none"><br clear="none"><a shape="rect" href="http://www.fot-racing.com/" target="_blank">http://www.fot-racing.com</a><br clear="none"><br clear="none">Donate: <a shape="rect" href="http://www.team.net/donate.html" target="_blank">http://www.team.net/donate.html</a><br clear="none">Archive: <a shape="rect" href="http://www.team.net/archive" target="_blank">http://www.team.net/archive</a><br clear="none">Forums: <a shape="rect" href="http://www.team.net/forums" target="_blank">http://www.team.net/forums</a><br clear="none">Unsubscribe/Manage: <a shape="rect" href="http://autox.team.net/mailman/options/fot/edwardbarnard@prodigy.net" target="_blank">http://autox.team.net/mailman/options/fot/edwardbarnard@prodigy.net</a><br clear="none"><br clear="none"><br clear="none"></div></div><br><br></div> </div> </div> </div></div></body></html>