1968 Ford XL Repairing Whilst Keeping It Roadworthy : 65 Large Bearing Ford 9-inch Overhaul - Welding Drain Plug


2023, November 14

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I left it overnight and this is the next morning. It's dry underneath, so welding successful.

Next I wanted a drain plug directly underneath for easy oil changes.

So here's the plan. A grade 8 nut with slots cut into it for drainage, then welded inside the housing.

TIG'd in place.

Now I want some skid rails to protect the plug.

This will work.

Leak testing the drain plug. I will have to order a longer magnetic drain plug.

Dry as a bone.

With the drain plug removed and the axle at roughly the angle as installed in the car, that's all the old oil that would be left. So this works really well for oil changes.

Now the backing plates with the worn shoe pads. I'll fill in the ruts with weld, grind and sand smooth.

Some of them are pretty deep, lots of city driving.

Here they are welded, sanded and sand blasted.

Time to start painting all the major and minor pieces. I just used POR 15.

Time to start assembling. First flat file all the mating surfaces to remove any burrs.

Same with the ring gear.

Then chase the threads in the ring gear.

Check each bolt by hand for smooth threads.

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