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Well, I was able to remove the drain bolt on the rear diff and I am happy to report there was plenty of fluid in there. Old fluid, but it was there . Since the drain bolt was not rounded out, but over sized for the 10MM, I was able to tap in an 11MM hex and that worked like a charm. The plug is now shaped to accept the 11MM perfectly. I will change it out when I get my new plugs just to be safe. Now to drive it and see if the noise reappears....so far it hasn't.

Just thought I would give my 2 cents, be sure to use anti-sieze on the plugs, with the dissimilar
metals the need that extra protection to prevent galling the aluminium case.

Oh...you only need about 8 ft./lbs torque.

Scott (IE) also sell a new style plug.

Best wishes

To add to this thread, and I am not sure this has any commonality with
berger's thread, but I also have a rather unusual noise, or better -- a
harmonic vibration. At a similar speed to berger, e.g. 90 KPH, there
is a rolling vibration, initially vibration free, then building up to a peak
shaking the rig, this repeats every 4-5 seconds. Yes, I have EX-1's,
but Scott at EI checked these out and in good shape. Brian at EI even
took his tires of his truck and tried them on my, same symptom, so
rim/balance doesn't seem to be a player here. This is just odd at this
frequency of 4 to 5 seconds, and very annoying -- I do like the gear
whining though. I also installed Jim's "Quietizer" on the tranny
mount -- no luck.

P.S. Berger, if your plug thread is stripped, I'd recommend Helicoil, I
used this on my 18mm-1.5mm O2 bung and it worked great -- tight
space on a Pinz header for this operation.

ron

I

Ron,
Yours sounds like maybe an out of balance internal driveshaft. Try engaging the first locker at highway speeds on a straight road. If it goes away when locked, then your driveshaft needs repair.

Thanks, I'll give that a try, although all shafts had been balanced,
but all ideas are very much appreciated!

cheers,