LSD oil change failure

[bluespeed]

After failing miserably to do what I thought would be simple job on car today.

 

I would greatly appreciate advice on how to remove the oil filler plug in my car's Diff. The Diff well may be a ZF in a Sierra casing (no markings obvious) fitted to a 2002 R300.

There are a set of what look like torx screw attaching the rear diff plate. I have T40,50,60 sockets and none fit.

Access to the oil filler plug with the Dion tube in place is also a challenge!

1. What is the size and type of the socket is the filler as I can't find anything that fits properly?

2. What is the best way to access the filler and undo it?

3. Are they normally very tight?

 

I have a pump to remove and refill the oil so once I get the filler plug undone all will hopefully be plain sailing. At the moment feel I have wasted a good afternoon’s holiday doing a 30min job!

Simon N

 

[Jonathan Kay]

Does this help?

 

Alcester Racing 7s

 

Jonathan

 

Edited by - Jonathan Kay on 26 Oct 2012 17:09:37

[bluespeed]

Jonathan,

Thank you for directing me to this article which tells me what I need to know. I will book another half day and buy a 10mm hex socket and try again next week!

 

Cheers,

Simon N

[Graham Howard]

Hi Simon

 

I find the best way to do this is to support the car on axle stands so that the de dion tube drops and the remove the boot floor. You can then get acces to the filler plug from above. I use a 10 mm Allen key and slide a 2 foot long piece of steel tube over the end. The plug then loosens easily.

 

Shouldn't take half a day!

 

Graham

[bluespeed]

Thanks Graham. Hadn't thought of taking out the boot floor. If I fail using the access method from along the Dion tube using a torque wrench, I will promptly whip out the floor.

Hope you are well,

Simon

 

 

[DJ.]

Removing the boot floor is definitely a good idea.

 

I find it helps to use a short section of allen key held in a Crow's foot wrench on a breaker bar. This means there is plenty of clearance. Most allen key socket drivers are too long.

 

Duncan

 

Edited by - DJ. on 26 Oct 2012 17:49:35

[bluespeed]

I think the floor method has it, will go straight there, thanks guys.

Simon N

[charlie_pank]

What about feeding the vacuum pump's tube down the breather?

[DJ.]

Quoting charlie_pank: 

What about feeding the vacuum pump's tube down the breather?

 

Unfortunately, the filler plug needs to be out to check the level when it is refilled.

 

Duncan

[charlie_pank]

My breather feeds into catch tank. When refilling I simply add the volume I took out of the diff plus what is in the catch tank. I would err on the side of too much, any excess will get blown out of the breather

[bluespeed]

The Diff oil changed successfully yesterday using the 'remove the boot floor method' all done in 80mins, many thanks for the tips.

'Another Caterham maintainance job completed with forum assistance'.

 

Simon N *biggrin*