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What tools are required for oil change of the diff and gearbox?


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Final drives either Ford or BMW both have levels plugs, neither have drain plugs so you will need to suck the oil out with and oil syringe from the likes of Sealey.

420 will most likely have a Caterham 6 speed or 5 speed Mazda gearbox, again both have level plugs, 6 speed has a drain, cant recall if the Mazda box does.

NB the Mazda box also requires a small quantity of oil i the selector tower too - Mazda forums will give you the detail on this.

 

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I sucked the oil out of my Ford diff via the boot with the car on the ground. Not sure about newer cars, but my part ply / part ally floor comes out by removing a few self tappers. I have cut the 'hoop' that goes around the filler neck so I dont have to disconnect the filler neck to get the ally panel out. Filling is easier using gravity too!

Have a look and weigh up the entry options! 
 

Ian

 

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Hi Iain, I know this looks a bit game of thrones :) - I found the clearance between the 6 speed gearbox and my tunnel a bit tight so hacked off an allen key then welded it to a bit of spare steel. This gives plenty of leverage in a small space and gets the fill/level plug out neatly.

Hope it helps on your mission. Tim

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As has been said Caterham's own 6 speed gearbox has a drain plug.  Both it and the filler/level plug are 10mm allen key but the filler plug access is very tight so you either need a tool such as Tim showed above or a cut down allen key that you can work with a 10mm ratchet spanner.

For the differentials you will need a suction pump if you are renewing the oil.

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Re #9:

...or a cut down allen key that you can work with a 10mm ratchet spanner.

As the ratchet spanner works in the one direction, take care that you don't trap it on the key as the plug unscrews. 

IIRC, a certain regular contributor didn't, and ended up with the key hard up against the tunnel side, with no way to screw the plug back in so as to release the spanner!

JV

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All interesting as on my 6 speed gearbox (1996) and yes, the level and drain plugs fit a cut down section of 3/8" Allen Key.  As John says take care if using a ratchet spanner.

I have just filled the box with Redline MTL using a Sealey plunger operated mini pump.  I was a bit sceptical how effective this would be as each stroke is about 10cc.  However it worked a treat to fill approx. 1.5 litres quite quickly.  The pipe comes with an alloy U bend at the end and there was just enough room to hook this into the filling hole in the narrow gap between the gearbox and tunnel.

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#17. Yes the Sealy pumps are quite good, I’ve been using one for both the box and diff since I built my car. 

A word of caution; I’m certain the the drain and filler are different sizes in many 6  speeds The fill is 3/8” and the drain 10mm. A cut off 3/8” will undo both but it’s a poor fit in the drain plug and there’s a risk of damage, it being about .020” smaller than it should be. 

 

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The important accessories are patience, limbo qualified & prepared to create some oily mess.

I know people do it but IMO accessing via the boot floor for the diff is as much if not more of a faff than just going 'up & under'.

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