GREAT - Now the tranny fill plug ...

Ramblin Fever · 07-01-2006, 12:27 PM

is leaking.

I do remember seeing a black type sealant that once was around the ring of the bolt on the fill plug when I pulled it off last weekend - well that sealant had begun to peel off, but I took a chance at not doing anything extra and just putting it back in.

Well, it's been dropping more and more fluid everytime I park, I initially thought the tiny leak at the seal above the handshifter was getting worse, but it's definitely the fill-plug bolt - cheap fix, hopefully.

I called Isuzu dealership looking for a whole new bolt (with black sealant), he said all I need to get is a new copper gasket/washer??

Does this sound right?

The pits of it is, this truck has to be driven 50 miles today, I'm in nice clothes, don't have time for another shower, and it bugs me as I know it's already lost 1/2qt if not more - easy! Oh, and I don't even HAVE a copper gasket here!!!

boaz2020 · 07-01-2006, 02:31 PM

This sounds correct, many drain plugs have copper crush gaskets that create a more than adequate seal.

You may be able to pick them up at either a automotive parts store or a hardware store, if you have another vehicle I suggest taking the bolt with you to test fitment. Just make sure the one you get isn't too much larger in diameter than the head of the plug. Also it should be a close fit around the threaded part of the bolt.

You can also try getting some Permatex silicon gasket maker and spreading a little (by finger) onto the flat inside head of the bolt before putting it in, alternatively you can try using standard silicon caulk sometimes referred to as RTV. AFAIK most if not all of it is oil resistant. Just try not to get a lot up into the trans pan.

-Phil

rodeo02 · 07-01-2006, 03:24 PM

Yes, the older pan bolts used a washer that had an o-ring bonded to it. The rubber tears away if they are loosened/tightened, forcing you to replace it. Later on they just went with a copper crush washer. My 2002 had copper crush washers. I never had a problem just re-using those. I never over torque them, so they seem to last, or you can just flip them over & use the clean side.

Joel

Ramblin Fever · 07-01-2006, 08:12 PM

Cool - well, it made it, almost wanted to unload the #500 pounds of play sand (in 50# bags) into the Xterra. But, I REALLY didn't want to.

I also didn't feel like driving all the way back into town once I got the Rodeo home, so I just bought a few different sizes of copper washers, one of them is bound to fit.

Tranny's way way too hot with this 98F heat we're having and with having driven it on the highway for a half hour each way - so I'll tackle it in the morning, and just do another drain/refill while I'm at it. That way I can be all done with getting most of the older (36k+ mile) fluid out.

I'm just glad it's a $.2 fix versus the $200 part for the seal that is weeping - thought I was going to have to replace it sooner.

Thanks!

Question though - while I have the actual drain bolt out, although it still has quite a bit of the black sealent on it remaining, should I put a washer on it anyway?

surferfletch · 07-01-2006, 09:28 PM

My fill and drain plugs have never had a washer, but some kind of thread sealant which I've never had to replenish. I like the copper washer solution better than sealant.

Gizmo42 · 07-01-2006, 10:10 PM

I think I would try to clean all the black stuff off. Might pevent the copper washer from sealing properly.

Ramblin Fever · 07-02-2006, 10:30 AM

ok, well, I ended up with some Gold washers - thought for sure they were copper in the store. One of these still ok to use, i.e. Gold washer?

boaz2020 · 07-02-2006, 11:51 AM

Gold??? Never heard of one. If you can get it to seal I'm sure almost any washer would work. Just remember, tight enough to prevent leaks and not vibrate out. Roughly 1/4 to 1/3 of a turn after the surface of the washer is contacting both the pan and the head of the washer. (ie: 17 - 22 ft. lbs.)

-Phil

Ramblin Fever · 07-02-2006, 02:28 PM

Ok, well I actually found 2 copper washers stashed away that came with my OEM oil filters for the oil drain bolt; they are about 1/2" in size - these are what I used on both transmission bolts, i.e. drain and filler plug. They're just a slight tad bigger then the threads, so we'll see.

For now, I put them both back in, filled her up, and there IS a very slight tad bit of weeping around both bolts, I've been ever so slightly giving each one tabs on the torque wrench, then waiting a few, etc.

This time, I had lost 1 qt in 1 weeks time - OUCH!!!

But, believe it or not, other then the crossmember, the underside of the truck is clean - how strange is that?

Ramblin Fever · 07-02-2006, 06:27 PM

Appearently I have a chronic case of UNDER-torqueing. After I shut the truck off earlier, thinking the bolts were done weeping, I come back out an hour later to find two tiny tiny puddles of ATF under both bolts.

Gosh darnit! Is what I was thinking, finally gave up and pulled out the torque/LB wrench, I had way under-torqued them.

All is good, took it into town 40 miles round-trip, shifts even nicer then when I swapped fluid out last week.

Beginning to believe Surferfletch - his opinion was his tranny shifts smoother everytime he exchanges fluid.

But, this is IT! At least for 10k or so, I must've gotten quite a bit of the old (36K+ mile) fluid out between these last two drain/refills, which equals a total of 3 drain/refills in the last 5mnths/6k miles. I'd say that's good enough for now, as the fluid was not much different then what came out of the bottle.

boaz2020 · 07-02-2006, 06:38 PM

Glad to hear everything is straightened out!

Good Job!

-Phil

surferfletch · 07-02-2006, 10:22 PM

I hope this is it for tranny threads for awhile. Everytime I see one I want to swap a few quarts. Tranny paranoia!

Ramblin Fever · 07-03-2006, 03:35 PM

Now, now Surferfletch, take DEEP breaths! It's alright....Kidding!

Honestly, if I wouldn't have had that leak at the gasket, I wouldn't have messed with the transmission, as it had 5 qts of new fluid, filter, and such; but the darn thing wouldn't quite weeping, and I can't stand a vehicle that marks it's territory on my driveway!!

The good thing is, is the fluid is most definitely clean and good for at least 10k miles or 3-4yrs before I'll accrue another 10k miles.

Blue Bowtie · 07-03-2006, 03:37 PM

There is a good chance that you got the largest percentage of the contamination out of the trans pan, at least. Anything else there which is ferrous should be stuck to the big magnetic doughnut, or will be too large to make it through the filter. And most of the potentially broken down oil should be fortified with fresh oil. Short of draining both pans, that's about the best you can do. Some people completely ignore their trans oil, so you're at least doing a lot better than that.

Ramblin Fever · 07-03-2006, 03:42 PM

Quote:

Originally Posted by Blue Bowtie

Some people completely ignore their trans oil, so you're at least doing a lot better than that.

Figure that's the least I can do - this tranny has had a hard working life considering it's size, and I never thought it'd make it this far, changing it's fluid constantly I guess, is the least I can do to see just how far I can go.

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