In order to fill and top off the gearbox on my Midget, I made a filler
assembly for less than $5.00 in about an hour. This is used from the
exterior of the vehicle, but could be used easily if one had access hole
in the interior.
MATERIALS:
2 each spring binder clips
1 each clear flexible pvc tubing (4')
1 each one-quart container for liquids
1 each hard plastic tubing (1")
1 each storage container (optional)
The binder clips are the black metal types that are used to clip together
a stack of documents; these come in a variety of sizes (able to hold a
1/4" stack of papers and up), I used the smallest. You could probably
use spring type clothespins. Cost: $0.20 (approximately, I already had
some).
The pvc tubing is the same as is used on aquariums; you want something
soft enough to pinch off easily. The inside diameter depends on your
container. Cost: $0.80 ($0.20 per foot).
The liquid container I used was a one-quart Rubber Maid one with a
flip-up spout and a wide mouth and lid; it was marked at various levels
which is handy for determining how much fluid you've added. Cost:
$1.50.
The storage container was also a Rubber Maid item; it's one of the
rectangular items, and I think it's one size up from the shoe storage
container. It holds the container assembly and a spare bottle of gear
fluid, and sits nicely in the boot or on a shelf (and if the fluid would
happen to leak, contains it). Cost: $1.75.
ASSEMBLY:
1. Vent the container.
(A). Poke a hole in the lid and glue the piece of hard tubing (I
used an old male-to-male vacuum line connector) through the hole so that
it extends about 1/2" inch on each side (and won't leak fluid).
(B). To the inside of the lid attach a piece of the flexible
tubing (mine was the same i.d.) so that, with the lid on, the tubing just
touches the bottom of the container, then cut the tubing off at an angle.
(C). To the outside of the lid, attach a piece of the flexible
tubing so that it extends in a gentle curve from the hard tubing in the
lid to about an inch past the outside bottom of the container. This is
the vent tube.
Note: The gentle curve is necessary so that this tube will not kink and
pinch off; but it's annoying to have it flapping around, so I slid an old
hose clamp around the tube at a point just slightly above the bottom of
the container and placed a zip strip around the container. This secures
the tubing while the clamp keeps the tubing from collapsing.
2. Attach the remainder of the tubing to the spout on the lid. This is
the fill tube.
3. Ensure that all tubing connections are secure and won't accidentally
disconnect.
4. Place one binder clip on the free end of the vent tube so that it is
pinched off. Place the other binder clip on the free end of the fill tube
so that it, too, is pinched off; this should be about three inches from
the free end of the tube.
USE:
1. With the vehicle's ignition off and parked on a level surface, place
the vehicle in gear, set the handbrake, and chock the wheels, then open
the bonnet.
2. Crawl under the vehicle and remove the gearbox fill plug.
3. Crawl out from under the vehicle and fill the container with the
desired fluid, and secure the lid. Make sure both binder clips are in
place.
4. Set the container upside down in the engine compartment so that it is
securely in place and will not tip over as you manipulate the fill tube.
I have a large hose clamp around the bottom of the container with an 'S'
hook attached; I hang this from my hood support so that the container
hangs upside down (looks like an IV bottle).
5. Snake the fill tube down through the transmission tunnel to the gear
box fill point. Avoid placing the tubing against the exhaust or any
other surface hot enough to melt the tubing.
6. Remove the binder clip on the vent tube.
7. Crawl back under the vehicle and Insert the free end of the fill tube
in the gear box filling hole.
8. Remove the binder clip from the fill tube, fill the gear box to the
desired level, and then replace the binder clip on the fill tube. Remove
the fill tube from the filling hole, and replace the fill plug. Wipe up
any spills or drips.
9. Crawl back out from the under car and and remove the container
assembly. Squeeze any excess fluid from the end of the fill tube, and
wipe up any spills or drips in the engine compartment. Replace the
binder clip on the vent tube and ensure that both binder clips are
secure. If the container has a flip-spout, flip it shut. Store
container assembly.
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