Modifying housing for elocked 3rd....
 

I bought an e-locked 3rd and I am going to modify the diff housing on my 96 runner to fit the new 3rd. I have found information on doing the actual modification and I have a friend at a machine shop who will help me do it. However, I need to get the housing off my truck so that I can take it to his shop and do the mod. Is there any good write up or advice that I could get on the best and easiest way to go about taking the old 3rd out and getting the housing out from under there. I will be working at my house and have basic tools and bottle jacks. thanks for any info.

i did mine under the truck. used an angle grinder and die grinder to trim the "slot" and drilled and tapped the new studs. no need to weld like others have. you could weld it if you wanted to but we felt that it wasnt needed. hasnt had any issues yet.

https://www.yotatech.com/forums/f31/e-locker-build-up-99419/ ?

adt,

that's my thread, but you can do a ton more reading if you search google, 4x4wire as well as this forum. of note, my tapping didnt go so well but if you read on page 3, robinhood's method worked perfectly. if you get your axle off and then tap the holes using the actual, bolted in e-locker diff as a guide, that would be the way i'd do it over again.

bob

oh, get more than 1 tap, we broke one, had to run and get another real quick. I made my dad come do it as I didnt want that responsibility

Also another trick is that if you do break off a tap while cutting new threads, the only think that can drill it out is a masonry bit (since it is carbide tipped as well). You can try to freeze and shatter it with a punch but it's very hard to do when there is so much other metal around it (acts as a heatsink).

I just use a broken tap extractor, very simple tool.......http://www.newmantools.com/walton/hpxtr.jpg

thanks for the info guys....actually, I think I will be fine because like I said I have a guy from a machine shop who is really good at doing this kind of stuff to help me. The main thing that I need help with is getting the axle housing out from under there. what should I use and how should I do it? are there any write ups or info on that? thanks

Yeah, those work the best unless the tap that broke was a smaller size (they aren't always easy to find though). You could also bring it to a machine shop and they'll EDM it out for you (but that ain't cheap) or if you have a plasma cutter, you could probably attempt it yourself. What I was talking about was definately more the shadetree mechanic method with tools most people already have, but using the extractor or other options as above is definately the preferred method IMHO. I'm sure we can all agree that breaking off a tap sucks, so don't use too much pressure, use lots of oil and blow out the chips often.