I've always paid somone else to change the front diff oil as I couldn't find it

[RobboMC Junior Member Find all posts View Profile Close RobboMC]

Step 1 - don't open the drain until you get the filler out, otherwise you are stranded.

Step 2 - the filler points forward and is a bugger to get out. Prepare yourself mentally for a good fight.

Step 3 - go to a reputable store and buy a good quality 10 mm hex key in a 3/8" drive socket,
and if you've not got one get a 3/8" drive breaker bar, a really high quality one,
not the rubbish that comes in the cheap socket sets, this a is a 4WD, not a slot car.
A ratchet may not fit and they are weaker as well, I tried and failed with a racthet.

Step 4 - lie under car with your head between the engine sump and the steering rack and stick your fingers up
and poke the hex socket into the hole; attach breaker bar and push upwards to rotate the socket anti-clockwise.
Pushing upwards works best as you brace yourself against the ground. Remove filler plug.

Chances are the mechanics haven't opened this either, it takes a lot of force. Cheap and crappy tools may not be up to the task.
If you can't get it out the consider giving up.

Step 5 - open the drain and catch the old oil. Replace drain plug!!!. Do not view the amount of oil that came out as an indication of what needs to go back in, it probably was not full.

Step 6 - refill using a tube running down from the engine bay, or a proper oil filler gun. Well worth the investment with 2 diffs, a transfer case and a gearbox to fill. Note the oil is different to the transfer case and different ot the rear diff. Get the right oil and get enough oil! One of the US oil brands makes nice 2.5 litre jars, or go halves with a friend. One litre won't be enough as you will spill about 1/2 litre in the process. Standing the oil in the sun for an hour makes it flow better and makes the job easier.

Step 7 - make sure the oil flows out of the filler when the diff is full - do not underfill. Put some anti-seize on the thread to make next time easier and replace filler plug to somewhere near correct torque.


I did this task successfully as I refused to accept defeat, but there is little or no working room between the front diff and the sump, the secret was the 3/8" tools, which I now find very handy on the rest of the cars in the stable.

[Brett1979 Avid PP Poster! Find all posts View Profile Close Brett1979]

I use the Nulon 1 litre oil bottles for the oils under the car because it comes with a handy extendable tube. You just pop the tube into the filler hole and squeeze the bottle until it's empty. Easy as and no messy spills. Only a little bit of squeeze pressure by hand on the bottle is needed to make the oil pour out of the tube. Previously I used to pour the thick diff oil down a funnel and or tube into the filler hole using gravity and man that was a messy time consuming job. Then I bought a Tom Thumb hand pump bottle and although easier, still a bit of a pain in the ass with minimal room under the car, and by the time you're onto the front diff after already doing the rear diff and transfer case you're arms are stuffed. Then I discovered the well designed Nulon bottles and I can't believe the other brands haven't copied the idea yet either. Until they do I won't use anything else under the car as I'm not drenched in patience.

I've had many issues with that (insert swear word here) front diff drain bolt over the years too. Mechanics have kept doing the bloody thing up too tight when I've requested they don't, then 10-20,000km later I've tried undoing it with my high tensile hex bolt and in the process kind of changed the shape of the hex nut hole after trying and trying and unsuccessful in removing it too because it's such a soft metal. Then had to get a mechanic to weld a bolt to the nut to remove it and fit a new nut after draining the oil. I again request they don't do it up too tight so I can easily remove it myself next time.... 10-20,000km later, same issue again. It drives me nuts.

[SOL Find all posts View Profile Close SOL]

Another option for the less than motivated is to get a windscreen washer reservoir with integral pump. Fill using that and a lead to the battery. Just a toggle switch to turn it on and off. Not suitable for real heavy oils but does work. Also used to back bleed brakes and clutches with same method.
SOL.

[croozza Avid PP Poster! Find all posts View Profile Close croozza]

I just go to my mates workshop and put it up on the hoist...lol