Filling a Differential
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There is always the thrill of trying to fill a Lotus Elan differential with fluid after it is installed ... Anyone else have an easier way?
I cut an access hole with a hole saw in the fiber glass bulkhead to the rear of the differential. If the hole was cut to the right size a Propshaft Access Grommet (p/n 026 B 0371) could be used. The filler plug in the differential should be filed to fit an 11/16" socket. It would make a very clean installation. - Michael Robertson
I had quite a bit of experience with this until I had the rear end rebuilt, fixing the leaky seal.
My technique involves the use of a pump designed for filling outboard motor gear cases. It is fairly compact, has a flexible hose and mine screws in to a wide mouth oil bottle.
With the pump available raise the car into a level position. For me this involves jacking and block the front of the car then pivoting the rear of the car to a level position, using one of those clever U shaped devices that lets you jack on the frame. After that, securely block the rear of the car, you will be spending a bit of time way under the car. The car should be fairly level. I always give it a test shake, believing it is better to lose a car than me and the car.
- Use an adjustable wrench to remove the fill plug, it has a square drive.
- Stick the hose in the hole and pump until the oil comes running out all over you and the car.
- Clean up the spilled oil.
- Assembly is the reverse of disassembly. - Dean Giacopassi