Manual Transmission Fill Bolt Stripped - Diesel Forum

dirtyb15 · 01-06-2013, 02:34 PM

Well, while i was under the truck today taking out the starter i decided i would replace the transmission and transfer case fluid. As soon as i saw the fill bolt, i changed my mind. Stripped pretty bad. Should i just fill though the shifter? If so how much fluid should i put in?

Any other tips?

Dr.Evil · 01-06-2013, 03:04 PM

Compared to the hex plug on the left side of the transmission it's a lot of messing around to remove the shifter boot and take the top plate off the transmission, but YES, you can add fluid that way, in fact many people recommend it because you can slightly over-fill your transmission.

My Factory HELM service manual says the ZF-5 takes 3.4 quarts of synthetic ATF, Mercron E6AZ-19582-B or equivalent meeting spec #ESR-M2C 163-A2. But I know some guys have put a full four quarts in them

dirtyb15 · 01-06-2013, 03:23 PM

well, if i could get the hex plug out i would love to fill it there

. Just went and got a 22mm 6 point, but i am gonna bet it is too stripped to remove with it.

**bugman** · 01-06-2013, 03:25 PM

You may need a pipe wrench that will lock onto the bolt head or you may try some heat. Then once you get it out you can always weld a large nut onto the bolt head to help you in the future.

dirtyb15 · 01-06-2013, 03:30 PM

Ahh, good idea for the pipe wrench. I may heat it as well. Thanks!

tickedoff36 · 01-06-2013, 03:41 PM

the other option (if it is pipe thread) is to go to the hardware store and get a new plug. i had to do this on my NISSAN. cheaper than buying a new plug.

greenskeeper79 · 01-06-2013, 04:06 PM

I've always filled through the shifter will every manual trans truck that i've owned. So much easier than making a mess below.

dirtyb15 · 01-06-2013, 06:11 PM

Well, could not get the plug out with heat and pipe wrench (hard to get a good grab on it.) Ended up draining and filling through the shifter which was pretty easy and not near as messy as what i did filling up the transfer case

. The house smells like ATF and my wife is not so happy with me

How many miles do you usually go before replacing tranny fluid again?

Ran out of time to do the differentials. I assume i have to pull the plate on the rear in order to drain? What about the front? How the heck to you guys fill these through the fill holes without making a horrible mess????

**klhansen** · 01-06-2013, 06:25 PM

Quote:

Originally Posted by dirtyb15

How the heck to you guys fill these through the fill holes without making a horrible mess????

I use a transfer pump. Cheesy plastic affair that I got for about $10 at the parts store. Has a suction hose and a discharge hose. It will suck out of the jug, but with quart bottles, I usually wind up knocking the bottle over and make a mess anyway, because it takes 2 hands to pump it. Last time I filled my tranny, I used gallon jugs which stayed upright better. As soon as it started running out of the fill hole, I removed the hose, stuck it in the jug and slapped the plug in place. Only got a couple of drips on the ground.

A plunger type pump that attaches to the bottle would be better, but lots of the bottles have different threads, so unless they come with bottle thread adapters, they aren't going to work with every brand of lube.

greenskeeper79 · 01-06-2013, 06:32 PM

Quote:

Originally Posted by dirtyb15

How many miles do you usually go before replacing tranny fluid again?

100k intervals, truck is an auto so I do 30k, TDI is a manual and won't be doing the second trans fluid change until 200k

fordsforever73 · 01-06-2013, 06:44 PM

As far as the stripped plug, I took a bolt and welded the threaded end to the stripped plug then used a wrench on it...worked perfectly. For filling t-case and trans I used the lid of a diff oil can, the pointed ones that you cut the tip off, they fit the trans oil cans. In some cases, I'll put a piece of hose of that lid (gotta do that while lid is dry not oily), that way the bottle can be placed in such a way, it can be squeezed easier.

For the diff's, the covers will have to be taken off. No drain plugs. Good time to do an inspection on gears and stuff while the cover is off. Also you can use a rag to clean out the bottom of diff...any metal will/can settle there.

**bugman** · 01-06-2013, 07:15 PM

The owners manual recommends that you change the transmission oil out at 30,000 mile intervals along with the transfer case on the manuals.

As for filling them Harbor Freight has a hand pump that fits into either a quart or gallon jug then you just pump it in with no mess.

Dr.Evil · 01-07-2013, 11:41 AM

Quote:

Originally Posted by tickedoff36

the other option (if it is pipe thread) is to go to the hardware store and get a new plug. i had to do this on my NISSAN. cheaper than buying a new plug.

Definitely NOT an NPT thread, it's a straight metric machine screw thread that seals with a soft aluminum or copper washer on the hex plug.

DIRTYB15 - changing the oil in the frt diff will be a challange, no drain plug and the diff case bolts to the one twin traction beam stamping. Most here have drilled a hole on a cast-in flat surface on the bottom of the diff housing, then tapped 1/4" or 3/8" NPT threads and installed their own plug. Rinse the housing out good before installing the plug in the new threads and adding the new oil.

**bugman** · 01-07-2013, 12:10 PM

You can purchase a oil pump either a 12 volt one or a hand pump and get a lot of the oil out of the front diff without removing the cover.

I have the instructions that Carpentractor had on his web site for drilling and placing a plug into the bottom the the Dana 50 if you want them.

dirtyb15 · 01-07-2013, 03:58 PM

Thanks guys, i may try using the pump and see how much i can get out that way. If you dont mind bugman, any chance you could email me that write up? (Or at least a picture showing where they put the drain hole in case i decide to go that route?)