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JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

TD5 gearbox level plug issue

Hi Folks,

I have been going through my 2006 TD5 replacing all fluids and filters and have only the gearbox remaining to finish the job.

The level plug however is totally knackered and I suspect will have to be removed at some time when the box is out of the vehicle.

Can any one advise an interim solution? can I fill the gearbox once drained via the gear-stick end being careful about the amount I add?

Advice appreciated as always

John

25th May 2016 10:19am

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2757

There's another plug higher up the side of the gearbox which l mistakenly thought was the level plug. Fortunately l realised before using the Defender.

However you could drain the oil then use that plug to put in the correct amount of oil.

Obviously you'd have to measure it in which should not be too hard as it comes in 1 litre containers.

Or you could fill it from the top as you suggested.

25th May 2016 5:21pm

JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

Thanks for the reply - will take a look shortly.

Quite happy as MOT passed without any issues apart from some weeping balls to look at!!!

28th May 2016 5:10pm

gazman

Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

I have the opposite problem. I can't get the lower one out. It's on my to do list when I do the seals.

Luckily mine leaks out so I just keep topping it up! 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r

28th May 2016 6:52pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2757

JOHNT01670 wrote:
Thanks for the reply - will take a look shortly.

Quite happy as MOT passed without any issues apart from some weeping balls to look at!!!

Most seem to have leaky balls. LR sell a "one shot" grease cartridge that you put into each side.
Being grease it does not leak out so much.

28th May 2016 7:57pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

oil level plug R380

Click image to enlarge

oil drain plug with mag

Click image to enlarge

28th May 2016 8:21pm

JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

Thanks for the response lightning - will get hold of some grease and give it a shot when I order a new filler plug (cheers DorsetSmith).

29th May 2016 4:01pm

grumpy old git

Member Since: 16 Nov 2013
Location: United Kingdom
Posts: 153

Make sure you buy genuine, the Br*tpart filler plug will wind right through into the gearbox......

29th May 2016 4:11pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2757

That would not be a good day!

1st Jun 2016 7:01am

JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

Cheers guys genuine LR plugs now in my possession.

Got her with a friend next weekend with access to hydraulic lift to see if the stuck plug can be removed or not.

12th Jun 2016 7:14pm

MrWisty

Member Since: 24 Mar 2016
Location: Shropshire
Posts: 3

I've just had the same problem with the R380 filler plug. Using a T55 driver started to chew the plug up, so I gave the problem to my garage. They tried die-grinding the plug socket out to T60 but it still wouldn't move. Finally they welded a large nut onto a short length of 3/8th bar and then welded the other end of the bar onto the filler plug. This got it out, but not before putting a very attractive twist in the 3/8th bar!

Why this filler plug doesn't have a standard 13mm square socket in it like all the other filler plugs is one of the great Defender mysteries - or is it charm?

25th Aug 2016 8:00pm

JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

Well done you - sadly mine is still stuck in place - will get someone to try the welded bar approach next!1

Agree with you totally about the T55 head plug

Is it possible to replace this with a standard square socket plug as used elsewhere?

26th Aug 2016 5:53am

MrWisty

Member Since: 24 Mar 2016
Location: Shropshire
Posts: 3

Only likely contender for an alternative filler plug is the one on the transfer box. I'll check this out when I get the TD5 over the pit for an engine oil change in a few weeks time and report back here. Don't hold your breath though!

26th Aug 2016 6:42am

MrWisty

Member Since: 24 Mar 2016
Location: Shropshire
Posts: 3

Sad to say the the gearbox filler plug is a "one-off" and can't be exchanged with any of the other filler/drain plugs on a Defender - at least not any on mine. Thank you JLR! 1999 Defender 90 TD5

18th Sep 2016 7:31am

JOHNT01670

Member Since: 24 Jun 2015
Location: CRAMLINGTON, Northumberland
Posts: 188

Thanks for checking this out for me - will ensure genuine LR plug replaces the damaged one

19th Sep 2016 10:19am

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