03 Rubicon front locker air hose fitting replacement

[03RESTORE]

My 90 degree air locker hose fitting on the front differential is loose and leaking. What is the best way to replace the fitting with a new one?
It seems like it is a press fit into the housing but what does the barb fit into inside the housing?
Can the fitting be pulled/pried out and a new fitting pushed/tapped back in? Or is it more complicated than that?
I'd like to fix the leak but I don't want to cause a bigger issue for my daily driver in the process.
Thanks in advance for any advise you can give.

 

[Jeepwx03]

Did you ever figure out a solution to this?

 

[LONGJP2]

Did you ever figure out a solution to this?

There is another barb on the inside.
It has another small hose attached to it, so don't pull it out before removing the diff. cover.
Are you leaking air or oil?

 

[Jeepwx03]

There is another barb on the inside.
It has another small hose attached to it, so don't pull it out before removing the diff. cover.
Are you leaking air or oil?

Mine's leaking air

 

[LONGJP2]

Mine's leaking air

I just seen recently that someone is making those now.
Unfortunately, I can't remember where I saw it.
If you can't find one or fix it, I might have a spare.

 

[Weasellee]

I am currently working on removing factory locker and installing Detroit in “my” rubicon front 44. If someone knows of a good way to plug this airline hole i will gladly send you my “fitting” as long as it removes well.
Anyone plug this hole?

 

[Jeepwx03]

I am currently working on removing factory locker and installing Detroit in “my” rubicon front 44. If someone knows of a good way to plug this airline hole i will gladly send you my “fitting” as long as it removes well.
Anyone plug this hole?

I would think while you have everything out you can tap the the hole and put a plug with some sealant on it. You should have a lot more room without the gears in the way and be able to clean the metal shavings out from tapping it.

 

[Weasellee]

An idea I did not thin

I would think while you have everything out you can tap the the hole and put a plug with some sealant on it. You should have a lot more room without the gears in the way and be able to clean the metal shavings out from tapping it

A great idea I did not think of

 

[LONGJP2]

I just seen recently that someone is making those now.
Unfortunately, I can't remember where I saw it.
If you can't find one or fix it, I might have a spare.

Found it.

 

[LONGJP2]

I am currently working on removing factory locker and installing Detroit in “my” rubicon front 44. If someone knows of a good way to plug this airline hole i will gladly send you my “fitting” as long as it removes well.
Anyone plug this hole?

Why not a rubber plug?

 

[Weasellee]

Why not a rubber plug?

Like a vacuum cap? Example of rubber plug that would handle the temperature and gear oil of that? Not sure if there is an animal

 

[LONGJP2]

Like a vacuum cap? Example of rubber plug that would handle the temperature and gear oil of that? Not sure if there is an animal

Some diffs actually have rubber plugs.
GIYF
https://www.google.com/search?q=rubber+differential+plug&sca_esv=b6238dc54ee7a2eb&sxsrf=ADLYWIJLUsNvOh7hGizAf1b9TMpxrj8mUA:1734574886569&source=hp&ei=JoNjZ_iZIKTG0PEPo9qQsQ8&iflsig=AL9hbdgAAAAAZ2ORNpheyZuO0KfhVv9sBmrfFJfTao-h&oq=rubber+differe&gs_lp=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&sclient=gws-wiz&safe=active&ssui=on

 

[AndyG]

Some guys have replumbed the internals with all hard line. Saw it on the internet.

 

[Weasellee]

I’m looking to cap off all the factory holes( but the did cover one) for install of Detroit locker. My question was suggestions for plugging the small air line or hole left if i remove it. Then if someone needs said removed airline id be willing to send it to them.

 

[Duner]

Found it.

View attachment 580012

Found and messaged Allen on Facebook on Sunday, sent me one on Monday, had it by today (Wednesday). Seems quality! He offers them in CRS or stainless, $60 vs $85, with free shipping.

Problem I have is mine is rusted off and idk how to get leverage top pop it out. Punch from the inside you don’t get great straight on leverage, and I fear snapping the end off and getting no leverage. Was thinking soaking with BP blaster / heating from the outside. Here’s a pic from the inside since I can’t find any pics.

 

[LONGJP2]

Never pulled one out. Worse case, you might have to drill out any remaining pieces. Also, PB Blaster is not a very good penetrant.

 

[Duner]

I know it’s not great but it’s what I got. Rust is a PITA

 

[sierradmax]

Thin brass punch and punch it out. Also, if anyone stumbles across this thread and doesn't feel like spending $60-$85, you can braze half a $5 brass 3/16" 90-degree hose barb fitting to the remaining piece, typically left in the housing.

 

[Duner]

Thin brass punch and punch it out. Also, if anyone stumbles across this thread and doesn't feel like spending $60-$85, you can braze half a $5 brass 3/16" 90-degree hose barb fitting to the remaining piece, typically left in the housing.

View attachment 652196

I have access to solidworks, was thinking of making a model people could use to 3D print. At the end of the day it’s low pressure air.

Did you punch it out from the inside? The gears make it hard to get a good angle to punch it out

 

[sierradmax]

Yes, it gets punched from the inside. It can be done with the locker and gears in the vehicle with careful punch positioning.

Good idea on a 3-D printed version!