removing gearbox fill plug???

[frenchwesty]

Might sound mad a bit tried to check gearbox oil and then once fill plug is off change the oil but do not want to drain then not be able to refill it again. But been trying to undo the fill plug on the side of the Box, but strain strain and the thing just will not move, Any advice for persuading it to move apart from getting the missus to nag it into submission??? Do not want to bugger up the plug and not be able to get it out at all!!!!

Thanks

Andy

[PetenAli]

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

I changed my gear oil last week - the filler plug was OK to get out but I had to use heat to free up the drain plug.

Worth doing though. There is also lots on the Wiki about which oil to use.

[Plasticman]

Id give the French nagging a go first
mike

[Hacksawbob]

if you can get a breaker bar on an extension you might be good for it, although it helps to have a second pair of hands holding the hex nut home while the other applies pressure, get the rear up a bit higher on a chock to give you a bit of working room. its luck of the draw if the breaker bar sits at a nice angle. Im pretty sure I did it with a big torque wrench once.

[joebee]

I used a double ended drain plug tool with a standard ring spanner set at an appropriate angle so that I could get a trolley jack under the spanner. Lifted carefully to just crack it open. Van was on level ground when I did this. Worked a treat.
Joe

[nevill3]

I changed my gearbox oil too this week, the filler plug was Ok but the drain plug was solid, I ended up using a large torque wrench to get the extra leverage required. Plus don't forget to wear old clothes that can be boil washed, the gearbox oil STINKS

[NicBeeee]

Hi

An old trick I use is to cut a tennis ball in half, hold it over the offending stubborn screw and strap it in place (ratchet strap or something similar). Drill a small hole in the side of the ball and spray lots of penetrating fluid in. Leave this overnight to do its thing and have anouther go the next day.

Good luck

[kevtherev]

With the correct hex key you can give it some grunt.

[frenchwesty]

Hi All

Cheers for the replies and advice, I have now got he correct hex key and was using before the 10mm hex bolt trick someone mentioned, anyhow will give it another go in the week with a big bar and after spraying with plenty of lubricant, hopeully will do the trick.

Then after that got a new caravanstore canopy on its way so another job for the week to, looks like my nights may be busy after work.

Cheers

Andy

[Plasticman]

they like some grunt.
M

[frenchwesty]

wooppeee found sometime to try to get the gearbox plug out again, and well bit of oil, large spanner and a even bigger hammer lots of banging a hey presto it moved and i got it out, when i did well some oil started to pour out a little so now know theres oil in there and the leak on the driveshaft is not that big, will keep an eye on it through the summer then fix the seal on the driveshaft to the gearbox after the summer.

well what next see what else i can fix!!! ohhh just recieved a new caravan store awnig so theres the next job fitting that!!! it has taken over my life lol

[aulday]

Hi guys

filled my gear oil last week and wanted to share with you how easy it was and how I did it.

I have a 1.6 JX TD and read accounts of it being stiff to remove and needing to remove the gear selector to do the job.

The way I did was very simple and took 5 minutes:

Jack Van up, remove RH back wheel
Lower jack onto jack stands, to the height the van is normally is with wheel on
From here you can see the filler plug
Get a long extension bar and push it through the pipes that obscure the filler plug (takes a bit of wagling but it goes through)
Attach your socket and plug key to the extension and insert to filler plug
give the extension bar a light few taps with hammer to ensure a good grip on the plug
Attach breaker bar and turn. bobs your uncle it's undoing
Fill using bottle and siphon tube (or shove 1 litre bottle directly in and squeeze using the tube on the lid)
Stop once over flowing and re-fit plug

Took 5 minutes no hassles