96k mile service

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wammers said:
Don't know how you got 7 litres in. Normal refill is less than 5. I take you did it on level ground.
Click to expand...

Oh I thought it was too low as RAVE says it's 9.7? Some of that 7 could well have been what was in my upgraded (rather large) delivery pipe.
Most level I have access to ie the road - spirit level indicated it was fine

Just driven her, and the good news is she's running fine so I haven't broken anything internally
The bad news is that it's weeping around the sheered bolt :'( Any suggestions for this.. Can I just drill through the screw?
 
TCubed said:
Oh I thought it was too low as RAVE says it's 9.7? Some of that 7 could well have been what was in my upgraded (rather large) delivery pipe.
Most level I have access to ie the road - spirit level indicated it was fine

Just driven her, and the good news is she's running fine so I haven't broken anything internally
The bad news is that it's weeping around the sheered bolt :'( Any suggestions for this.. Can I just drill through the screw?
Click to expand...

They are 6 mm you need to drill 3.2 mm (1/8") no larger, down the centre and use an easy out. But be careful, break the easy out in the bolt and you will never get it out.
 
wammers said:
They are 6 mm you need to drill 3.2 mm (1/8") no larger, down the centre and use an easy out. But be careful, break the easy out in the bolt and you will never get it out.
Click to expand...


Depending which of the bolts it is, for some of them there's enough metal lip around for new holes with bolt and nut to hold it together leak free:)(Experience from previous car):eek:
 
TCubed said:
Gearbox is done.... I'm afraid to say it was an utterly miserable 3 hour experience :(
I followed the excellent guide on here, but the bolts were a nightmare to get off.. and then getting on.. blueughhh took 3 attempts to get it in the right place and then 1 of the retaining bolts sheered :/ So it's running on 5 which I hope holds it.. I've left the underlay off so I can check over the coming days.
It took about 7 litres of fluid with the engine running.. which seemed a bit low but it was coming out at that point. When it starting leaking out it was not a pleasant colour.. kindof orangy.. Is that because the remainder of the oil that didn't come out initially got flushed out then?
Anyway.. 48000 miles (hopefully!) until I need to go through that again!
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You have only partially changed GB fluid, do it again in a wee while and more of it is new. Better still. do it frequently and your GB will love you:)

Tip do it twice with not long in between first time you do it if you see an odd colour old stuff, no need to change filter both times and get a sprayer or pump, makes it nearly fun. Also change the diff. oil again if you didn't clean the gunk out with a finger or rags through the drain hole, but for heavens sake get a pump or the 1 liter cans with spout as mentioned.:)


Hilka 500CC Oil Suction Gun, hand suction pump gearbox, sump oil removal | eBay




DSCF9070.JPG My designated ATF "garden" sprayer:cool:
 
TCubed said:
Gearbox is done.... I'm afraid to say it was an utterly miserable 3 hour experience :(
I followed the excellent guide on here, but the bolts were a nightmare to get off.. and then getting on.. blueughhh took 3 attempts to get it in the right place and then 1 of the retaining bolts sheered :/ So it's running on 5 which I hope holds it.. I've left the underlay off so I can check over the coming days.
It took about 7 litres of fluid with the engine running.. which seemed a bit low but it was coming out at that point. When it starting leaking out it was not a pleasant colour.. kindof orangy.. Is that because the remainder of the oil that didn't come out initially got flushed out then?
Anyway.. 48000 miles (hopefully!) until I need to go through that again![/quote]
Should be done every 24K miles. Dead easy job to re-fill using a modified garden sprayer:)
Click to expand...
 
Druim said:
Depending which of the bolts it is, for some of them there's enough metal lip around for new holes with bolt and nut to hold it together leak free:)(Experience from previous car):eek:
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It's the front right bolt (curved)
How safe is it to drill a new hole if possible, I really don't want to pierce the box! :eek:
 
TCubed said:
It's the front right bolt (curved)
How safe is it to drill a new hole if possible, I really don't want to pierce the box! :eek:
Click to expand...

It may not need drilling out if it is not bottomed. Which it should not be. Try using a sharp pointed punch and see if you can gently tap it round. On the bolt only a couple of mill in from the edge. When you get enough protrusion a pair of pliers should do the rest. Sump bolts are only 8 nm or 6 lb ft. So they are finger tight plus a small cough. Sneeze and you'll bust them. But you know that now don't you.
 
wammers said:
It may not need drilling out if it is not bottomed. Which it should not be. Try using a sharp pointed punch and see if you can gently tap it round. On the bolt only a couple of mill in from the edge. When you get enough protrusion a pair of pliers should do the rest. Sump bolts are only 8 nm or 6 lb ft. So they are finger tight plus a small cough. Sneeze and you'll bust them. But you know that now don't you.
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Yes I know that now :p
I checked RAVE and they're only meant to be tightened to about 8Nm or similar.. so I get why I broke it
It's only the screw part which is stuck in though.. I still have the half with the bolt attached
 
TCubed said:
It's the front right bolt (curved)
How safe is it to drill a new hole if possible, I really don't want to pierce the box! :eek:
Click to expand...


Best thing is of course to get old screw out, I couldn't with tools available so drilled a new hole not far from it as there was plenty of metal in that place, think it was 2nd from rear left. Not sure there's enough space next to your broken one so I would concentrate on getting old broken bit out.


BROKEN STUD SCREW BOLT EXTRACTOR SET EASY OUTS REMOVAL | eBay
 
Always do the four corners to steady the sump then concentrate on the others why do people always over tighten things:mad: try nipping a nut and bolt together as least as you can with a pair of spanners and see if you can undo it with your fingers ! Bet you can't
 
Grit Valve said:
Always do the four corners to steady the sump then concentrate on the others why do people always over tighten things:mad: try nipping a nut and bolt together as least as you can with a pair of spanners and see if you can undo it with your fingers ! Bet you can't
Click to expand...

I overtightened these because they were an utter nightmare to get off (rust duhhh :rolleyes: ) so I thought they needed to be tight
Live and learn I guess
 
TCubed said:
I overtightened these because they were an utter nightmare to get off (rust duhhh :rolleyes: ) so I thought they needed to be tight
Live and learn I guess
Click to expand...

Only the bolts would have been rust you could clean thread or replace the the gearbox sump face is aluminium isn't it so no rust there .
 
Ah yes so you did - I misunderstood
I will give this a go when my back recovers.. I pulled a muscle getting the jammed filler plug out :/
 
Well the combination of hurting my back and hitting my head on the road caused me to snap and go to my local (over the road :p ) garage.
Slightly disappointed I didn't complete this myself but they sorted the bolt problem and also did the transfer box oil for me, so she's good for a while :)
I think for future I'll leave undercar stuff to the guys with a ramp!
 
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