Jack I. Brooks wrote:
>
> Guys and gals,
>
> When I had the tranny out, for other problems, I never thought about
> loosening the gear box refill plug; chalk it up to inexperience. Yeah, the
> tranny is in, everything is buttoned up except the tranny cover and the plug
> refuses to budge. I've soaked it, heated it, pryed it and spent several
> hours last night, 'till 1:00 AM, attempting to turn the square plug into a
> round one.
I have several choices. Tonight I will try to get the plug to
> move with a more penetrating lube and center punch or cold chisel, the plug
> is already toast.
Since it's already wasted, why not get the largest pair of Vise Grips you can
buy, and just clamp htose bad boys on as hard as you can sqeeze, then get nasty
and just pull 'till it starts moving. I can't beleive that would still be
unable
to do the trick...
> In the unlikey event that I can't get it out and since my
> credibility as a fine part time mechanic, with the missus and several
> neighbors is on the line, I am contemplating popping the top off the tranny,
> while it is in the car, and filling the gearbox up to the bottom of the
> plug, leaving the frozen plug problem to be solved at a later date. < Maybe
> by a NO, new owner? :-) >
I strongly recommend AGAINST that. With the interior still out it's got to
be easier now than the next time. I mean, after all, you may just decide to
keep
this car for over a year, right?, and you really should check the tranny at the
very least at the beginning of every riding season (or year, for you perpetual
summer people).
Besides, what makes a mechanic a "fine" mechanic, is the way he/she reacts to
problems. EVERY mechanic runs up against problems or mistakes, the real test is
how well (how well, not how fast, which comes later-with expeirence) he/she
resolves
the problem. Like whether this mechanic hacks his way through, or repairs
things cor-
rectly.
>
> Since the tranny top removal idea came to me on the way to work today, I
> have not yet checked the manual (my excuse for asking what I perceive is a
> marginally stupid question). My question is can I simply remove the 8
> bolts, remove the tranny top, add the Gear lube (Redline 75-90NS) up to the
> bottom of the fill port and replace the tranny top?
Yes, I suppose you could do that. (Shaking my head)
>
> My concern is pulling and replacing the tranny top. Is there anything to
> look out for or make sure of alignment? Obviously, I am not going to slide
> gears around, just open, look around, pour and close. Should I make sure I
> do it in neutral? Anybody see any problems.
Put the tranny in neutral, undo the eight bolts, noticing there are THREE
sizes.
(two 2 5/8" for the front, four short ones in the middle, and two 2 5/8" for the
rear) then lift the cover away. Put in your oil, put on a new gasket (I usally
rub a little permatex into paper gaskets to "help" them seal) then carefully
lower
cover back on. The trick here is to make sure the shift forks go into the
grooves
of the respective engagement/synchro hubs. The difficult trick here is the
reverse
selector. The lever in the tranny moves around real easy, so make extra sure
that
it is fitted into the reverse fork properly as you lower the top onto the
tranny.
Then just tighten up the bolts, and hope the tranny dosen't have any leaks
in
the rear or front seals, at the seam of the tail/main case or in the gasket at
top,
cause it will be a real pain to refill it again this way...
JOE IV
TR 250
WALLINGFORD, CT. USA
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