I finally decided to change the fluids in my diffs & xfer case last night. I've only had it ('02 limited) a year, it has 104,000 miles, and I'm pretty sure they've never been changed. First problem is I couldn't get the fill plug off the rear diff. Luckily I hadn't remove the drain plug, so I'll tackle that another day. Transfer case fluid didn't look too bad for 104k miles, but when I drained the front it was dark grey and there was something resembling grease on the end of the drain plug. Anybody know what that might be? I wiped it off and refilled the diff with Amsoil Severe Gear and drove it about 25 miles. I put it into "4wd" several times and everything seem fine.

 

You need a breaker bar to get the fill plug off (more leverage) but don't round off the corners. Then I'd suggest replacing the fill/drain plugs on everything with these...much easier to get on/off. I replaced all of mine on both vehicles, 85 and 87.


The stuff on the end of the drain plug was fine metal shavings pieces that collected on the magnet...which is normal.

http://www.wabfab.org/products/diffe...ferentials.htm

 

Make sure you use a 6pt 24mm socket instead of a 12pt 24mm so you don't round the rear diff plug.

 

I was hoping it was just shavings, but it looked like grease to me. I'm anxious to see what the rear looks like.

All I had was a 12pt and I had read warnings about rounding the plugs. That's why I didn't try the breaker bar. I'll try to find a 6pt 24mm (two Sears stores haven't had them) and use a breaker bar. The ones on the transfer case came off fairly easy.

Will the part from WABFAB fit the rear fill & drain holes? Do I need the steel or aluminum washers?

Thanks for all the help.

 

Yep, they'll work flawlessly. I even sell the 10mm allen head socket.

From the website:
"Magnetic Drain Plug
Magnetic Drain Plugs are a great way of keeping metal from building up in the oil. Low profile design uses recessed 10mm Allen socket. Your choice of Aluminum or steel washers. Aluminum washers are designed for transfer cases, and aluminum transmissions (G, W & R series). Steel washer is designed for axle housings (differentials) and steel transmissions (L series)."

 

When i changed my diff oil, I thought that was silicone or grease at first. Then after playing with it, I found out it was just metal filings in oil. Cool stuff.

 

I changed mine and had the same thing on the drain plug. Don't sweat it. Like already said, most of it is very fine metal shavings.

I didn't have any problems lossening the plugs. I used a 6 point socket with and actual breaker bar and had absolutely no problems. I know you never can tell, but I bet if you get a 6 pt socket and decent breaker bar, it will come off easily.

I changed mine about this time of year. I learned one thing-do it when it is warmer. It is sooo much easier to pump the gear oil when it is warmer outside.

 

The only place that I found a 6pt 24mm was a deepwell at Advanced Auto Parts. I looked everywhere 2 so I thought I would give you a heads up.

 

I use a metric impact socket set I got from Harbor Freight, 10-24mm, all 6 sided, 1/2" drive:

http://www.harborfreight.com/cpi/cta...temnumber=7383