Differential Cover Solution to Brake Line Support

[Elevator Man]

If you've ever gone to replace the stock differential cover with an aftermarket one, you may find a problem with attaching the brake line support to the aftermarket cover. The stock cover uses two bolts with studs on them to hold a plastic clip that supports the brake line. See images below of a removed stud and the stock diff. cover with the stud removed. One side of the stud holds on the diff cover and the other is used for attaching the plastic clip that supports the brake line.

A lot of aftermarket diff. covers use recessed allen bolts to protect the bolt heads from getting damages on rocks. This presents a problem for supporting the brake line because the stock studs won't fit into the aftermarket covers so there isn't anything for the brake line supports to clip onto. If you don't want to leave the brake line unsupported, there isn't an obvious way to use an aftermarket cover with recessed allen bolts and support the brake line.

The solution I decided on was to buy some bolts from the local hardware store and weld them to the diff. cover to make my own studs. See images below. Hopefully this helps you out if you run into the same situation.

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[brkdncr]

Wouldn’t welding in those areas introduce a sealing weakness?

 

[swamp2]

Cool. No concern about the welding distorting the cover?

 

[Elevator Man]

Wouldn’t welding in those areas introduce a sealing weakness?

No, the cover is very very thick, it's not sheet metal. I'd guess it's like 1/2" thick without measuring. Also, it's pretty much only a few tack welds so you aren't putting much heat into the part.

 

[Elevator Man]

Cool. No concern about the welding distorting the cover?

No, the cover is very very thick, it's not sheet metal. I'd guess it's like 1/2" thick without measuring. Also, it's pretty much only a few tack welds so you aren't putting much heat into the part.

 

[Fmuguira]

Hopefully the cover manufacturers take note and modify their full production/design to incorporate the OEM hardware and/or use newly manufactured hardware that takes the brake line OEM mounting into consideration !!

Doesn’t seem like a big “ask” when a guys forking out 200-300 clams ……

 

[CarbonSteel]

What is the OAL of the OEM studs?

Couldn't you just use a longer stud with a Torx end like these?

https://belmetric.com/m8-torx-drive-double-end-stud-class-8-8-steel/?sku=S8X51TXGRN

 

[redone17]

I just added a few small washers for my ARB.

 

[CarbonSteel]

I just added a few small washers for my ARB.

Is that a drain plug at the bottom right of the cover? If so, is it magnetic?

 

[PWillette]

I have the ARB and can confirm that is a drain plug and it has a magnet.

 

[Elevator Man]

What is the OAL of the OEM studs?

Couldn't you just use a longer stud with a Torx end like these?

https://belmetric.com/m8-torx-drive-double-end-stud-class-8-8-steel/?sku=S8X51TXGRN

This would work for holding the brake line, but since the stud has no nut on it, the stud wouldn't do anything to secure the housing so it wouldn't work.

 

[CarbonSteel]

This would work for holding the brake line, but since the stud has no nut on it, the stud wouldn't do anything to secure the housing so it wouldn't work.

It would--install the stud, put a nut to hold the cover, slip the plastic part over the remaining stud and put a lock nut to hold the plastic part

 

[Elevator Man]

It would--install the stud, put a nut to hold the cover, slip the plastic part over the remaining stud and put a lock nut to hold the plastic part

That sounds like a reasonable solution. You don't need anything to hold the plastic brake line holder. It just slips over the stud and uses compression to hold on. I like your solution though, maybe it'll help someone.

 

[CarbonSteel]

That sounds like a reasonable solution. You don't need anything to hold the plastic brake line holder. It just slips over the stud and uses compression to hold on. I like your solution though, maybe it'll help someone.

After pulling my cover, I am not sure how long those compression "tabs" inside will last and in typical OEM fashion you have to buy the whole brake line to get the clips as they are not sold separately.

I am looking at finding a better solution to hold the brake line because (at least for the short term), I plan to pull the cover a number of times to change the fluid.

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