Gearbox oil refill plug.

Drivetrain problems

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Gearbox oil refill plug.

Postby Monty » Thu 11.08.2005, 16:34

Since i`ve been having a whining sound and it looks like it could be the drive shaft bearings i was looking at the parts manual and noticed there was a page showing a Bolt for oil refill on the gearbox (above the nearside drive shaft), now i thought thats got to be be better than taking the speed cable out. So when i took the gearbox out of Pinky 1 there she was (see pic).

With my noisey gearbox on pinkyII i was told to try changing the oil, couldn`t believe it there`s no refill plug on PinkyII just a blank plate. so had to do it the old fasion way (speed cable out) and it`s made no difference to the whinning.

If u`r doing a gearbox oil change, 1st see if there is a refill plug. :roll:
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Last edited by Monty on Sun 26.11.2006, 20:34, edited 1 time in total.
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Postby Paul.P » Thu 11.08.2005, 19:40

Nice one Monty. I know there wasn't a bolt on blacky because we had engine & gearbox out & couldn't work out how to fill gearbox until read in the manual about speedo cable. Maybe it was only on the earlier models ?
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Postby Monty » Thu 11.08.2005, 19:43

strange cause pinky II is slightly older :roll:
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Postby Paul.P » Thu 11.08.2005, 19:47

What year are your Pinky's, Blacky's a late J reg !
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Postby Doug » Thu 11.08.2005, 21:02

before I were to use the fill hole (if it's there) I'd use the recommended way and fill properly, and then remove the fill plug and compare the fill height of the oil to see if it is indeed correct. Since this tranny is in other makes ans cars, the fill hole may or may not be appropriate for us ? ?

But I do like fill holes :roll:
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Postby Monty » Thu 11.08.2005, 23:16

Pinky 1 is a 91 and Pinky II is a 90.

Doug the fill plug looks like its inline with the speedo cable hole
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Postby DeeAitch » Tue 02.05.2006, 19:07

The D shaped plug is definitely screwed in and the same thread / O ring as the drain plug. On the attached pic you can see, from the top down 'D' shaped plug, new 'Filler plug' & new Drain plug. All are new Lotus supplied parts.
If you buy a new 'filler' plug it comes with a Hex head which you are meant to shear off to prevent using it again as a filler plug! :evil: However if you buy a new Drain plug it comes with the handy info 'Fill engine oil' embossed on it! Screw it into the filler hole - make sure to get a new 'O' ring for it - and Bob's ya Marley :P Not sure it's much easier to get to tho'
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Postby Doug » Tue 02.05.2006, 19:28

nice, Dave.

how about measuring the 'new fill plug's' thread size, pitch, and length -- then we can just find a hex head bolt/plug to fit instead.

you could gring the edges of the Lotus new fill plug so a wrench will fit it in the future though
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Postby Monty » Tue 02.05.2006, 19:38

Dico and i have done the same thing, think dico got it from SW or SJ`s and is the same as the drain plug and comes with a O ring already fitted. :-D The worst thing it`s a 24mm bolt head :roll:

The one i pictured above of pinky1`s gearbox was a bolt head welded on but sheard of when i tried to tighten it up :roll:
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Postby DeeAitch » Tue 02.05.2006, 22:33

No need for grinding etc - just buy a drain plug and use it as a filler plug, it looks like one anyway as it says 'fill engine oil'. At £3 from lotus it won't break the bank. Also getting a regular bolt with a shoulder and groove to accept an 'O' ring won't be simple. I'll measure it anyway and you can decide.
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Postby Dico » Wed 03.05.2006, 21:16

The 'O' ring needs to be purchased seperate.

I agree that it may not make refilling much easier :?

I'll let you know in 30,000 miles. :P
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Postby Monty » Wed 03.05.2006, 23:32

Dico wrote:The 'O' ring needs to be purchased seperate.

I agree that it may not make refilling much easier :?

I'll let you know in 30,000 miles. :P


ops thought they cane with the O ring, so how much did u pay in the end then?

Think it will be easy cause u don`t have to remove the speedo cable but will have to use a flexable tube to refill.
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Postby DeeAitch » Thu 04.05.2006, 10:08

It's M20 x 1.5p
Having done it twice now thro' the speedo hole it is not really that hard. Big problem for me was cleaning the area and the fear of dropping something down the big hole you get when the speedo is pulled.
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Postby joeisuzu » Sun 26.11.2006, 19:54

I JUST read about how these cars have to have the tranny filled through the speedo cable, that has got to suck! On my Impulse with basically the same engine and transmission, there is a fill and a drain plug on the same side of the tranny. You just put a tube in there and fill it until the oil comes out, and its full! WAY easier than useing the speedo cable hole on my car, as it is AWD and the speedo cable has an extension on it that goes into the transfer case for for the driveline to the rear wheels...

Now that I think about it, the fill hole even has a little upturned kneck in it and then the plug to make filling that much easier! My geo storm however does not have this upturned kneck and I use a clear tube to fill it. Hoever as my old transmission in my impulse recently bit the bucket and is now sitting in my back yard I can take the little upturn for the filler hole and fit it to my Geos tansmission as they are identicle externally...
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Re: Gearbox oil refill plug.

Postby dickendoe » Sun 30.12.2012, 03:33

Hi

keen to change the gearbox oil, anyone have a pic with the fill plug in place so I can check before taking the speedo cable out? Mention of a pic above but can't see it?

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Re: Gearbox oil refill plug.

Postby ccb056 » Sun 30.12.2012, 07:02

Here's what it looks like with the speedo cable in place:

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I slightly loosened but did not remove the bolt to the right to swing the metal plate around and then pulled out the speedo gear cable.
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Re: Gearbox oil refill plug.

Postby KenS » Tue 02.02.2021, 18:46

Resurrecting a fairly old thread - does anyone know how easy the D shaped 'fill plug' is to remove? Is it likely to come out with mole grips or best to make a fitted D style ring spanner? Then, is it known for sure that filling through this does give the correct level? Looks like there are lots of M20 x1.5 sump plugs on ebay to close it off with.
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Re: Gearbox oil refill plug.

Postby KenS » Fri 05.02.2021, 17:46

I had no luck removing the fill plug with mole grips, so welded up a tool from tube + flat steel + 1/2" socket. The plug then came out fairly easily using this with an impact driver. Just hope this fill hole is at the same level as the speedo dip stick.
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Re: Gearbox oil refill plug.

Postby lotustonybassplayer » Fri 08.10.2021, 13:45

Hi Ken is your tool :shock: available for hire as i am planning on changing the oil in the gearbox after 9 years of ownership :oops: ,and it appears i have the D shaped fill plug fitted to my car aswell. Tony
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Re: Gearbox oil refill plug.

Postby KenS » Thu 14.10.2021, 19:23

Hi Tony, just dug it out from the garage, how quick do you need it, I can stick it in the post tomorrow morning so could be with you Monday or Tuesday, PM the address for posting if that works. If you need it for the weekend, we could drive it over on Saturday. Let us know. - I have replaced the D plug with a normal drain plug so don't want it back, you can be the custodian :D
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