Checking the gear box
Draining and filling the gear box
can easily be done by a competant DIY person.
You can see at the end of the
transmission, a ballooned cover. Note where it is bolted onto the
transmission housing, you'll see a square idented plug that is larger
than the rest securing the balooned cover. This is the level bolt and
can be checked by the owner easily. See picture
and link below.
Clean around the bolt first, then remove
the bolt. If the oil dribbles out, then the level is OK
The level is the actual plug aperture,
fill until it comes out of the hole, it's that easy. Remember
to have the Boxer sitting on level ground.
To drain the gear box is a simple
proceedure. Just remove the drain plug. The drain plug is similar in
appearance to the level plug. See picture for
location of plugs.
It's possible to get more into the gear
box by using a measured extra, then quickly fitting the plug back.
This I'm told could be useful to ensure the 5th gear which is placed
higher in the box, and will improve it's ability to get the
'Splashed quota of oil.
I'm told the modern oils do not require
additives, as we used to add in the old days. They might even negate
the oil properties! I was told adding 'Additives' reduce the tight
clearances of the gears and cause more problems than cures.
The oil I used even mentions the point,
'Additives not required.'
I found this one of the easiest jobs to
do, as long as one does not mind lying on the floor to remove the
plugs and re-filling the box. It took me about 1/2 an hour. and will
last at least 3 years, at the mileage we do.
The oil removed was black, the new oil was
almost as clear as water! One of the reasons for doing it myself, I
know the job has been done.
The drain plug has a magnetic tip, which
collects metal residues.
Gear Box Cover and oil Level bolt
Hint: The drain pipe
from the passenger side vent drops down and over the gearbox. It has
been known for this pipe to 'point' to the gear box. Causing water to
seep into the gear box with it's inherent problems, for example
taking the surface off the gears and other damage. Check it and
secure it away from the gear box. A sure sign it has been
contaminated, if the oil has a milky appearance.
I have fitted an extension pipe, which is
pushed inside the original pipe and extended down below the chassis.
I then secured this extension pipe with tie clips.
Never labour the engine in 5th gear. This
one of the reasons for a 5th gear failure. As soon as the speed drops
below 60mph, change down to 4th gear. My vehicle is 15 years old now,
2013, and I have not had any 5th gear problems yet!