Gearbox Clutch CVs CV joints drain plug

Plug Removal

douwes: 17 mm hex required. Just Kampers J11205 on the tools list. If you take a M10 bolt of about 2 cm and you put on that two nuts turned against each other, you have an adaptor you can use with your normal spanner. I hope you get my drift...

NB. Make sure you can remove your fill plug before you remove the drain plug, or you'll be stuck with a van with an empty gearbox!

This plug was very tight (seized in) and had to be freed up by punching around with a bolt/nut drift to shock it loose, before driving the correct 17mm hex plug tool into it to finish unscrewing it. A replacement drainplug looks in order!

Refilling

Mocki I use 1/2" garden hose about 3ft long and a funnel it fits, pass the hose down frm the engine bay, the funnel sits on the top of the air filter and dribbles the oil in over a period of time.

Tip: Warm the oil gently first, it flows better, quicker and doesn't stink as much - just dont get caught using the kitchen appliances by the missus

Magnetic plug fir tree

This is fairly typical of a long service box, no large chunks, nor lots of bronze, but obvious long-term wear.

Better the particles are on the plug than in the oil.

Fill procedure in images

Hacksawbob

Filling a diesel box here, the procedure is basically the same but the access may be slightly different on a petrol. I found there was room above the gear selector to get my standard socket in and remove the plug. But then I knew it would come out easily as I only did it 2 years ago and used copper slip on the threads. Also I have the rear of the van raised slightly on camping chocs I am on a hill so these chocs made the van level. Manual gearbox takes 4.5Litres of oil, and it is not recommended to overfill, on a level van you can fill til oil is level with fill hole. but I purchased a 4.55L container from GSF so I knew I had the right ammount to go in which helps. The chocs just gave me a couple of inches of working space under the van which makes all the difference. If you are not on a hill then raise the front up similarly or the box wont drain/fill fully.

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gearboxfill plug, remove 1st above gear selector input

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17mm hex socket with short extension, there is room above the box to pull down

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Gearbox drain plug

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magnetic drain plug with 2 years of wear since last change

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Funnel and hose through rear wheel arch.