Club 80-90 Forums

evening all, nice to be typing to you.

well, the gearbox filler plug is well and truly furbled, so, seeing as I have the engine (1.9 dg 1983 ) out, this is not a disaster, (I hope).

I have , as I see it, three options.
1 /get a refurb box
2 /take out the box, empty the oil thru the drain plug, then refill the correct amount thru same plug, and re-fit.

3/ and this is what I intend trying first. leave box in situ.
drain the oil.
refill thru the drain plug by means of a long filler tube sealed at the drain plug which will be well sealed from spillage and vented from the top of the oil container.
oil will be very warm (as normal), and - hopefully will result in little spillage when re-fitting the plug.
some loss will be preferable to what I have now, so I will be happy with that.

any thoughts on this plan?

and yes I do know how to spell through

i would fill it with the box out and upside down, Can you really not get the filler out?

Get a pic up of the plug I'm sure somebody will have suggestions
Usually can weld something to it to get it out
Got to be easier than taking the box off
You may be able to fill from the drain but not easy

Infidel,
My old boss did just that with a rear axle on a morris. Filled it slightly over full then whipped out filler tube and banged in the bung before any great ammount had run out. I have a worn bung to remove myself at some stage.The hex is partly rounded and the walls of the bung are a bit thin. I'm hoping to mig a 17mm hex piece of bar in and put spanner on bar. Here's hoping.

lloydy wrote:i would fill it with the box out and upside down, Can you really not get the filler out?

no, I tried heat,to very nearly cherry red.

the spanner is new, but wouldn`t have it even with a two foot breaker bar, then I tried using the centre - punch method, but that stripped most of the hexagon, so its not an option, unless someone knows better.

however, I am not in despair, the job can last as long as it takes.
I am enjoying this re- furb very much

lloydy wrote:i would fill it with the box out and upside down, Can you really not get the filler out?

no, I tried heat,to very nearly cherry red.

the spanner is new, but wouldn`t have it even with a two foot breaker bar, then I tried using the centre - punch method, but that stripped most of the hexagon, so its not an option, unless someone knows better.

however, I am not in despair, the job can last as long as it takes.
I am enjoying this re- furb very much

itchyfeet wrote:Get a pic up of the plug I'm sure somebody will have suggestions
Usually can weld something to it to get it out
Got to be easier than taking the box off
You may be able to fill from the drain but not easy

yes, welding a tool onto the plug crossed my mind, but that can sometimes end in tears, so I have temporarily discounted that method.

blacky wrote:Infidel,
My old boss did just that with a rear axle on a morris. Filled it slightly over full then whipped out filler tube and banged in the bung before any great ammount had run out. I have a worn bung to remove myself at some stage.The hex is partly rounded and the walls of the bung are a bit thin. I'm hoping to mig a 17mm hex piece of bar in and put spanner on bar. Here's hoping.

well. fingers crossed for you, and thanks for the post.
very much appreciated.

Brickwerks used to sell these for the job but I think the webshop may be out of stock at the moment ...

itchyfeet wrote:Brickwerks used to sell these for the job but I think the webshop may be out of stock at the moment ...

absolutely bloody silly idea.

the vodka would fall out of the fridge.

there is of course the fact that every time I need to replenish the g/box oil, I will need to remove the engine and gearbox, so the idea of re-filling through the drain plug is not an ideal solution.

you can also fill via the reverse switch hole but it takes a long time as the oil has to pass through three small holes in the selector shaft bush to get into the box, but it has been done, ideally you want an adapter that will screw into the switch housing

@ infidel, where are you located?

what2d wrote:@ infidel, where are you located?

Poole, why?

Aidan wrote:you can also fill via the reverse switch hole but it takes a long time as the oil has to pass through three small holes in the selector shaft bush to get into the box, but it has been done, ideally you want an adapter that will screw into the switch housing

now this sounds like plan!
any idea where I would get hold of an adaptor, or do I make it myself?

first of all of course, I have yet to attempt removing the drain plug

been to Vanfest to pick up a few bits, one of which has taken me four years to locate, so I shall be tackling the drain plug tomorrow.