hexrain

1994 22re truck (manual) 2wd

So here is my problem. I doing a clutch for the first time today. Got everything disassembled, with not near enough of the right tools, but I digress. So i set my tranny aside (a little off level) and where the driveshaft connects in the back, a milky oil mixture starts leaking out. I looked it up, and apparently since my 270k truck still had stock clutch and pressure plate (and i'm assuming gear oil too) there must have been 270k worth of condensation in there.

So I went to open it up and apparently the previous owner had stripped out the fill bolt. I tried cranking it, pb blaster, putting the wrench on and hammering a breaker bar to loosen, dremmeled it down to a 16mm from 17mm, and no luck just stripping it more. the thing is super stuck. tommorow is sunday and i have to have this truck up and running by monday morning at 5:30 for work.

So now to the questions. should i just flush it with some gear oil and then put 2.5 quarts in it (i read this is the capacity) through the shift hole? is there another way to judge the level besides having the fill plug open? is it bad if i put too much oil in there? is it reasonable to suspect that my rear diff. is in the same state assuming it hasn't been changed? what is the best way of freeing up this bolt?

Thanks Yota warriors!

lethe

I don't remember what the capacity is off the top of my head but i would fill it through the shifter hole like you mentioned. Thats how i do it.

hexrain

thanks for the response. any idea of what could happen if i overfill? judging by what happened i imagine the extra would just leak out around the driveshaft.

hexrain

also, from reading about it, i guess no oil should be escaping around the output shaft... so do i need to replace that then also, or might i have just unseated it when pulling the driveshaft?

Shagool22

Weld a clean not stripped bolt head to the fill plug and get it out. Then go to www.marlincrawler.com and order new fill and drain plugs. Very cheap. I highly recommend ordering a shifter seat as well!! Takes a lot of slop and play out of shifer

lethe

Changing the seal on the rear output of the transfercase is easy. A impact wrench will make removing the staked nut a lot easier.

hexrain

awesome suggestion shagool, hadn't thought of that! but in the meantime since i dont have access to a welder for a good while i still need to get a feel for capacity and whether overfill will harm anything. i dont have an impact unfortunately.

RSR

You can always have a new bolt (head) welded to your old... Probably the easiest way to to do it. Then remove and replace...

Shagool22

I believe mine took 3-3.5 quarts. Als lost as your in the 3quart range that outta do until you can take care of the stuck fill plug

Shagool22

I don't think a little overfill will hurt anything, if you completely over fill it might be hard on the seals I'd imagine that being the only harm you could do.

Shagool22

Sorry I just re read your post and realized your 2wd.. If you read capacity is 2.5 qts then put that much in and call it good until you get a chance to look into removing the full bolt

Mr. No SPAM

How does the height of the fill plug relate to the height of the rear seal area? If the rear opening is about the same height on the tranny as the fill plug is you could leave the drive shaft out and fill until the oil comes out where the seal goes, or over the over the seal lip itself.

It also makes sense to just fill it with whatever quantity you determine is correct and call it good.

hexrain

i put a little more than 2.5 in but i also changed the seal. im think its probably good but im going to end up changing the fluid again soon, as i think there is probably more milky oil still remaining.

i test drove after the new clutch and it is awesome! i think my clutch must have been going out the whole 4 months i have had the thing. it took out all the hesitation i was having and it has way more acceleration. just awesome all around! that was kind of an intimidating job to do by myself for the first time but im stoked that it went great. who needs a tranny jack anyway... good thing the tranny only weighs like 100 pounds.

Shagool22

Glad you got her rippin again. Good job, and yes a brand new clutch is one of the greatest feelings haha

grumpin

Great! Nice when it works out well!

hexrain

I ow have a weird rattle, clang, possible grinding going on after the change. I have a post in 2wd forum. I need help!

Shagool22

Could be a number of things.. Did you torque flywheel and clutch plate to spec? Something could have come loose. You're gonna have to pull her apart and take a look!!