JX seized gearbox filler plug (5 speed)

[fixitsteve]

Tried everything to undo it including a impact driver, but it won't budge. Is there another way of putting oil in maybe through the reversing light switch holder on the opposite side. There are three bolts holding the unit on, will any thing fall out if i take it off ? If i drain it completely i'll know how much to put in to fill it up.

[Aidan]

if you have to you could do it that way, but you'll have to partially remove the selector shaft in order to get decent access as the bearing cup inside there is an interference fit in the case and only three small holes in it so trying to fill through the reverse switch hole will take for ever

You will have to remove the gearshift rod from the box at the rear onion and separate the cup and ball, then undo the m8 nut and remove the ball from the end of the shaft, ensure the box is in neutral when you do this, ball is vertical.

remove the three m7 bolts holding on the reverse switch housing, there will be some oil in there and a spring attached to the cover , there may be a paper gasket if late box, usually sticks to the cover

then push the selector shaft from the nearside and it will pop out the other side, it will stick in most instances and be reluctant to fully emerge, when there's just the threaded part of the shaft showing on the nearside a firm tap with the hammer will pop it out the other side, once the bearing cup pops out of the case you will have a nice big gap to get a hosepipe in, 3 1/2 litres should be plenty


this could be wikied to save me writing it again in future

there is a very slight chance of popping the seal on the offside out of the case when you push the selector shaft back in but usually they stay put, jiggle the selector shaft gently as it goes back in to get it to allign through the selector shafts - the slotted bracket should be on the engine side when you slide it in with the slot parallel to the floor

good luck

[CovKid]

Added to WIKI for you Aidan - agree it needs a permanent spot. Will try to add obvious comments about removing filler before draining:

https://club8090.co.uk/wiki/Ge ... earbox_oil" onclick="window.open(this.href);return false;

[Plasticman]

Do you know any body shops with an inductive heater, will get it shifted no probs
mike

[Aidan]

depends if it's mullered, if it is then heat won't help, as the tool no longer fits, only way is on the bench with a chisel drift

[Red Westie]

With anything this tight I would use an air gun but with a short 1/2 inch extension (the type that allows a T bar to be inserted) then load with the T bar at the same time as impacting...
A bit of heat can help as well.

Martin

[Plasticman]

agreed aiden but op implies not as has tried ID to shift it
M