Doing my elocker retro today on my 3rd gen 4runner I drilled one of the holes a little off. I am trying to decide how best to handle this. Any suggestions?

I have considered enlarging the hole on the 3rd member. I figured this would not upset the alignment of the diff since the other studs and holes will remain.

Will that work? Thanks in advance.

 

You're probably better off welding the hole shut, grinding it flat, then redrilling in the right spot. Someone else chime in on this suggestion.

 

just drill it out and tap in a larger bolt? depends on how off it is...and how much room you've got to the edge of the flange

 

You misdrilled the hole for the stud? If it isn't very far off (like just doesn't quite line up) I would probably enlarge the hole on the 3rd, use a slightly larger washer, and make sure you get gasket sealer all around that area. If its a 1/4" or more off I'd probably have it welded up and start over. I'd be more concerned if you drilled it too close to either edge of the mounting face... if its just clocked wrong probably not as big of a deal.

Got pics?

 

Yes its one the upper hole, behind the locker motor. It's definitely less than 1/4", I didn't measure though, it I'll get pics tomorrow morning.

 

One of the long studs that goes through the locker motor? I messed mine up a little bit, and just drilled out the mounting holes in the locker motor and everything is fine. If its off too bad you'll have to fix the holes.

 

Here are the pics. The problem hole is the one that is marked by black ink around the gasket. It is off by a 1/16" would be my guess. A small amount but enough to not line up nicely with the hole on the 3rd. It is also possible the upper "long stud" is off slightly too, but the 3rd goes on fine if I removed the upper "short" stud that is marked in the pic.

 

If the gasket still fits, it's not off by enough to matter IMHO.

Drill out the hole on the third and call it good.

 

I'm about to order 2 new TRD elockers to do this same mod on my 85 4Runner.

The stud looks very close. My opinion without photos was to weld and redrill but I think you should just drill out the third and bolt it up. The only reason not to do that is if you bought a new third with a warranty.

Curious as to how you marked the holes. My plan was to do the trimming, welding and flattening on my axle housing and then bolt down the third with all the studs that aren't being replaced. I then plan to mark the centers through the diff, remove the diff and drill. Also plan on drilling in a drill press using a level to get the diff mating surface level.

Hopefully they will be right.

 

The common way is to use the gasket, but bolting up the third is probably more accurate.

 

Every thread that I've read where they used the gasket resulted in alignment problems. Most advise not to use the gasket as it's not accurate enough. That's why I was curious as to how Taro marked the holes.

 

I bolted up the 3rd and used a transfer punch on 3 of the 4 holes. With the top most hole the locker motor is in the way and I couldnt use the punch. I was nervous about removing the motor completely so I marked that hole using paint through the 3rd. Removed the 3rd and then I punched the paint mark. I reinstalled the 3rd to verify but when it came time to drill I didn't line it up right and my hole was off.

I think I marked it correctly but drilled wrong. I think the housing may have moved as I drilled. It is very difficult, at least it was for me, to line up the drill bit and hold the housing steady. I really took my time, this part took longer than anything else for me.

 

I always drill out the holes in my 3rds to make them easier to install and remove. Its enough work wrestling one of those into the housing without having to fight lining studs up with the holes. Especially with my ARBs, just one slip and you damage the hard air line.

 

We miss drilled one of the short holes, and are planning to enlarge the hole on the diff

 

I enlarged the diff holes for 2 of the new stud locations. I used a bit that was very close to the size of the hole in the gasket. Worked fine and I bolted it up tonight. I'm letting the sealant overnight and plan to finish it up tomorrow.

Thanks for all the replies.